Trane CSRA025FAF0, CSRA040FAF0, CSRA060FAF0 Installation And Maintenance Manual

Installation
Operation
Maintenance

25, 40 and 60 Ton Air-Cooled
Cold Generators®

Models:

CSRA025FAF0,
CSRA040FAF0, and
CSRA060FAF0

© 2002 American Standard Inc. All Rights Reserved

CSRA-SVX02A-EN

Table of
Contents

General Information

Earnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Literature Change History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Overview of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Model Number Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Unit Nameplate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Evaporator Barrel Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Compressor Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Input Devices & System Functions. . . . . . . . . . . . . . . . . . . . . . . 9

Unit Component “Layout” and “Ship with” Locations . . . . . . . . 15

Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Installation

Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Unit Dimensions & Weight Information. . . . . . . . . . . . . . . . . . . 16

Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Leveling the Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Shipping Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

General Unit Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Chilled Water Piping Requirements . . . . . . . . . . . . . . . . . . . . . 23

Main Electrical Power Requirements . . . . . . . . . . . . . . . . . . . . 24

Chilled Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Final Water Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . 26

Freeze Protection from Ambient Conditions. . . . . . . . . . . . . . . 26

Electrical Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Electrical Cable Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Cam-lok Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Pig-tail Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Flexible Hose Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Dixon Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Hard Pipe Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Field Installed Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Circuit Breaker External Handle . . . . . . . . . . . . . . . . . . . . . . . . 38

Main Unit Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Power Wire Sizing and Protection Device Equations . . . . . . . . 41

Field Installed Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Controls using 24 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Controls using DC Analog Input/Outputs . . . . . . . . . . . . . . . . . 44

Controls using DC Communication Links . . . . . . . . . . . . . . . . . 45

Ice Building Control Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

System Pre-Start Procedures

Voltage Imbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Electrical Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

2 CSRA-SVX02A-EN

Table of
Contents

System Start-Up

Chilled Water Circulating Pump . . . . . . . . . . . . . . . . . . . . . . . . 59

Verifying Proper Fan Rotation . . . . . . . . . . . . . . . . . . . . . . . . . 63

Compressor Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Proper Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Compressor Crankcase Heaters . . . . . . . . . . . . . . . . . . . . . . . 72

Low Ambient Damper Adjustment . . . . . . . . . . . . . . . . . . . . . . 72

Final System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Service & Maintenance

Compressor Operational Sounds . . . . . . . . . . . . . . . . . . . . . . . 75

Scroll Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . 75

Fuse Replacement Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Coil Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Annual Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Final Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

CSRA-SVX02A-EN 3

General

NOTICE:

Information

Warnings and Cautions appear at appropriate sections throughout
this manual. Read these carefully.

-

WARNING

if not avoided, could result in death or serious injury.

CAUTION

not avoided, may result in minor or moderate injury. It may also be
used to alert against unsafe practices.

Indicates a potentially hazardous situation which,

-

Indicates a potentially hazardous situation which, if

CAUTION

property-damage-only accidents.

–

Indicates a situation that may result in equipment or

Literature History

CSRA-SVX02A-EN (May 2002)

Original issue of manual. Describes the Installation, Operation and Mainte­nance procedures for the unit.

Reference: CGAF-IOM-2 (Non-rental CGAF Chiller)

Overview of Manual

Note: One copy of this document ships inside the control panel of each unit

and is customer property. It must be retained by the unit's maintenance
personnel.

This booklet describes proper installation, operation, and maintenance
procedures for air cooled systems. By carefully reviewing the information
within this manual and following the instructions, the risk of improper
operation and/or component damage will be minimized.

It is important that periodic maintenance be performed to help assure trouble
free operation. A maintenance schedule is provided at the end of this
manual. Should equipment failure occur, contact a qualified service
organization with qualified, experienced HVAC technicians to properly
diagnose and repair this equipment.

4 CSRA-SVX02A-EN

General
Information

Important Note: Environmental scientists have found evidence that

refrigerant emissions contribute to depletion of ozone in the upper
atmosphere and can increase global warming. Trane encourages every
effort to eliminate, if possible, or vigorously reduce the emission of CFC,
HCFC and HFC refrigerant to the atmosphere that can result from
installation, operation, routine maintenance, or major service on this
equipment. Only technicians with EPA certification should be allowed to
handle CFC, HCFC or HFC refrigerants. Compliance or certification to other
local or state codes may also be required when handling refrigerants. Always
act in a responsible manner to conserve refrigerants.

Model Number Description

All Trane products are identified by a multiple-character model number that
precisely identifies a particular type of unit. An explanation of the
alphanumeric identification code is provided in Figure 1a. Its use will enable
the owner/operator, installing contractors, and service engineers to define
the operation, specific components, and other options for any specific unit.

When ordering replacement parts or requesting service, be sure to refer to
the specific model number, serial number, and DL number (if applicable)
stamped on the unit nameplate.

Unit Nameplate

The ChillerSource unit nameplate is located on the panel adjacent to hinged
chiller control panel door. It includes the model number, serial number,
electrical characteristics, refrigerant charge, as well as other pertinent data.
A Mylar and small metal chiller nameplate with the Model Number, Serial
Number, and Unit Weight is located on the outside upper right corner of the
control panel door. An additional nameplate is located on the inside of the
control panel door. See Figure 1b.

When ordering replacement parts or requesting service, be sure to refer to
the specific model number, serial number, and DL number (if applicable)
stamped on the unit nameplate.

Evaporator Barrel Nameplate

The nameplate is located on the top of the evaporator barrel near the supply­end tube sheet. The word “Nameplate” is stenciled on the insulation. To view
the nameplate, remove the tape over the area and spread the insulation. Re­tape the insulation after viewing.

Compressor Nameplate

The nameplate for the “Scroll” compressors are located on the compressor
lower housing.

CSRA-SVX02A-EN 5

General
Information

Figure 1a — Model Number Description

6 CSRA-SVX02A-EN

General
Information

Figure 1b — Unit Nameplate

Unit Description

Before shipment, each unit is leak tested, dehydrated, charged with
refrigerant and compressor oil, and run tested for proper control operation.

Each unit is equipped with manifolded scroll compressors. Each manifolded
set of compressors is piped in parallel and utilizes a passive oil management
system to maintain proper compressor oil level.

The condenser coils are aluminum fin, mechanically bonded to copper
tubing. Copper-fin coils are optional. Louvered condenser grilles for coil
protection are standard.

Direct-drive, vertical discharge condenser fans are provided with built-in
thermal overload protection.

For “Ship with” items, refer to the Unit Component “Layout” and “Ship with”
Locations illustration.

Low ambient dampers are provided for low ambient operation.

CSRA-SVX02A-EN 7

General
Information

The shell-and-tube type evaporator used in each air-cooled Cold Generator
is manufactured in accordance with ASME standards. Each evaporator is
fully insulated and equipped with a drain connection. The chilled solution
temperature sensors are located on the solution outlet and the return
solution end of the evaporator.

A liquid line solenoid valve, filter drier, sight glass, thermostatic expansion
valve, and service valves (liquid and discharge) are provided on each circuit.

Standard controls for these units is a microelectronics control system that
consists of a network of modules referred to as Unit Control Modules (UCM).
The acronym UCM is used extensively throughout this document when
referring to the control system network.

These modules through Proportional/Integral control algorithms perform
specific unit functions that governs unit operation in response to chilled
water temperature leaving the evaporator. The stages of capacity control for
these units is achieved by starting and stopping the compressors.

They are mounted in the control panel and are factory wired to their
respective internal components. They receive and interpret information from
other unit modules, sensors, remote panels, and customer binary contacts to
satisfy the applicable request for cooling. Refer to the following discussion
for an explanation of each module function.

Human Interface Module (HI - Standard)

The Human Interface module enables the operator to adjust the operating
parameters for the unit using it's 16 key keypad. The 2 line, 40 character
LCD screen provides status information for the various unit functions as well
as menus for the operator to set or modify the operating parameters.

Cold Generator Module (CGM - Standard)

The Cold Generator Module (CGM) responds to cooling requests by
energizing the proper unit components based on information received from
other unit modules, sensors, remote panels, and customer supplied binary
inputs. It initiates unit operation based on that information.

Compressor Module (SCM & MCM - Size Specific)

The Compressor module, (Single Circuit & Multiple Circuit), upon receiving a
request for mechanical cooling, energizes the appropriate compressors and
condenser fans. It monitors the compressor operation through feedback
information it receives from various protection devices.

Trane Communications Interface Module (TCI)
(Used with Trane ICS™ Systems)

The Trane Communication Interface module allows external setpoints for
most of the unit functions to be communicated to the unit's UCM network via
a Trane ICS™ system or a Tracer Summit™ system. DIP Switch settings on
the TCI module for these applications should be; Switches 1, 2, and 3 are
“Off”.

8 CSRA-SVX02A-EN

General
Information

Generic Building Automation System Module (GBAS)
(Used with Non-Trane Building Control System)

The Generic Building Automation System (GBAS) module allows a non­Trane building control system to communicate with the unit and accepts
external setpoints in form of analog inputs 0 - 5 DCV and a binary Input for
demand limit. Five (5) binary outputs are available on 0 - 5 DCV modules.
Refer to the “Field Installed Control Wiring” section for the control wiring to
the GBAS module and the various desired setpoints with the corresponding
DC voltage inputs.

Current Sensing Module (CSM)

Current transformers located around two (2) of the main power leads for
each compressor monitors the running current during compressor operation.
The information is sent to the CGM and can be accessed through the
“Compressor Status” submenu displayed at the Human Interface Module.

Input Devices & System Functions

The descriptions of the following basic Input Devices used within the UCM
network are to acquaint the operator with their function as they interface with
the various modules. Refer to the unit's electrical schematic for the specific
module connections.

Lead/Lag (Standard)

When Lead-Lag is enabled, for each capacity add request, the CGM will
begin sequencing the compressors “On” that have:

A. the least number of starts; or,

B. the least run time (if number of starts are equal)

At each capacity subtract request, the CGM will begin sequencing the
compressors “Off” that have:

A. the most run time; or,

B. the least number of starts (if more than one compressor has the same run

time)

If a compressor is locked out for any reason when a capacity add request
occurs, the next available compressor which meets the specified criteria will
be started.

If a compressor can not be turned “Off” due to the minimum “On Time”, the
next compressor which meets the specified criteria will be turned “Off”.

On dual circuit units, as the first two capacity add requests are initiated, one
compressor on each circuit will start before any additional compressors on
any circuit is started. When staging down from three compressor stages to
two compressor stages, the CGM will turn the compressors “Off” on the
circuit that has the most compressors operating.

CSRA-SVX02A-EN 9

General
Information

With Lead/Lag enabled, HGBP operation (if applicable) will be bypassed and
the system will go directly into pump down when the last subtract command
is initiated.

When the UCM is powered up (after a power loss), or any time the
compressor's start time and run time are equal, the lead compressor for
single circuit units (20 through 30 Tons), will be the first “On” and the lag
compressor will be the first “Off”. For dual circuit units (40 through 60 Tons),
the “On” sequence will be A-C-B-D and the “Off” sequence will be D-B-C-A.

Loss of Flow (Refrigerant) Control

Is accomplished using a binary input device (LPC) located on the suction
lines near the scroll compressors.

The LP cutouts are designed to open if the suction pressure approaches 7 ±
4 psig. If the LP cutout opens after a compressor has started, all
compressors operating on that circuit will be turned off immediately and will
remain off for a minimum of three minutes.

The LPC contacts are designed to close when the suction pressure exceeds
22 ± 4 psig. If the LP control is open when a compressor is requested to
start, none of the compressors on that circuit will be allowed to operate.
They are locked out and a manual reset diagnostic is initiated.

If the LP cutout trips four consecutive times during the first three minutes of
operation, the compressors on that circuit will be locked out and a manual
reset diagnostic is initiated.

Saturated Condenser Temperature Sensors (Standard)

Are analog input devices mounted inside a temperature well located on a
condenser tube bend. They monitor the saturated refrigerant temperature
inside the condenser coil and are connected to the compressor module
(SCM/MCM). As the saturated refrigerant temperature varies due to
operating conditions, the condenser fans are cycled “On” or “Off” as required
to maintain acceptable operating pressures.

Head Pressure Control (Standard)

Is accomplished using two saturated refrigerant temperature sensors.
During a request for compressor operation, when the condensing
temperature rises above the “lower limit” of the controlband, the Compressor
Module (SCM/MCM) begins sequencing condenser fans “On”. If the
operating fans can not bring the condensing temperature to within the
controlband, more fans are turned “On”. As the saturated condensing
temperature approaches the lower limit of the controlband, fans are
sequenced “Off”. The minimum “On/Off” time for condenser fan staging is

5.2 seconds. If the system is operating at a given fan stage below 100% for
30 minutes and the saturated condensing temperature is above the
“efficiency check point” setting, a fan stage will be added. If the saturated
condensing temperature falls below the “efficiency check point” setting, the
fan control will remain at the present operating stage. If a fan stage cycles

10 CSRA-SVX02A-EN

General
Information

four times within a 10 minute period, the control switches from controlling to
the “lower limit” to a temperature equal to the “lower limit” minus the
“temporary low limit suppression” setting. It will utilize this new “low limit”
temperature for one hour to reduce condenser fan short cycling.

High Pressure Controls (Standard)

High Pressure controls are located on the discharge lines near the scroll
compressors. They are designed to open when the discharge pressure
approaches 405 ± 7 psig. The controls reset automatically when the
discharge pressure decreases to approximately 300 ± 20 psig. However, the
compressors on that circuit are locked out and a manual reset diagnostic is
initiated.

Low Ambient Control

The low ambient modulating output on the compressor module is functional
on all units with or without the low ambient option.

When the compressor module has staged up to it's highest stage (stage 2 or
3 depending on unit size), the modulating output will be at 100% (10 VDC).
When the control is at stage 1, the output (0 to 10 VDC) will modulate based
on the saturated condensing temperature.

When the low ambient damper option is installed, the dampers will modulate
according to the output to control the saturated condensing temperature to
within the programmable “condensing temperature low ambient control
point”.

Status/Alarm Output (Standard)

Is an internal function within the CGM control module that provides;

A. diagnostic signals to the Human Interface Alarm LED.

B. control of the binary Alarm output.
C. control of the binary outputs on the GBAS module to inform the customer

of the operational status and/or diagnostic conditions.

Compressor Circuit Breakers (Standard)

The Scroll Compressors are protected by circuit breakers which interrupt the
power supply to the compressors if the current exceeds the breakers “must
trip” value and opens a set of auxiliary contacts in the control circuit.

When the Compressor Module (SCM or MCM) detects the open auxiliary
compressor contacts, it turns any operating compressor(s) on that circuit
“Off”, locks out all compressor operation for that circuit, and initiates a
manual reset diagnostic.

CSRA-SVX02A-EN 11

General
Information

Compressor Motor Winding Thermostats (Standard)

A thermostat is embedded in the motor windings of each Scroll compressor.
Each thermostat is designed to open if the motor windings exceeds
approximately 221°F. The thermostat will reset automatically when the
winding temperature decreases to approximately 181°F. Rapid cycling, loss
of charge, abnormally high suction temperatures, or the compressor running
backwards could cause the thermostat to open. During a request for
compressor operation, if the Compressor Module detects a problem outside
of it's normal parameters, it turns any operating compressor(s) on that circuit
“Off”, locks out all compressor operation for that circuit, and initiates a
manual reset diagnostic.

Low Ambient Compressor Lockout (Standard)

When low ambient compressor lockout is enabled, the compressors are not
allowed to operate if the temperature of the outside air falls below the
lockout setpoint. Compressor operation is enabled when the temperature
rises 5°F above the lockout setpoint. The setpoints and enable/disable
option is programmable at the Human Interface inside the unit control panel.
The default setting is 30°F.

Note: The unit is wired so the CGM monitors incoming power for proper
phase sequencing. Observe proper polarity of internal wiring during service
procedures.

Short Cycle Protection (Standard)

If compressor operation is interrupted by a loss of power or by a manual
reset diagnostic, a minimum of one minute must elapse before the affected
compressor(s) will be allowed to restart for “Process” applications. A
minimum of three minutes must elapse before the affected compressor(s)
will be allowed to restart for “Comfort Cooling” applications.

Hot Start (Load Limit) Control (Standard)

Each time the system is started and the control of the CGM transitions from
“Loop Stabilization” to either “Process” or “Comfort Cooling”, if the Leaving
Solution Temperature (LST) is higher than the programmable Hot Start Load
Limit Setpoint (HSLLS), the lag compressor on each circuit will be prevented
from operating until the leaving solution temperature is lowered by 5°F below
the HSLLS.

If the Hot Start Limit time interval elapses before the LST is 5°F below the
HSLLS, the control will transition immediately into the Hot Operation mode.

Hot Operation mode is programmable to:

1. Do not limit capacity, initiate an informational diagnostic until the LST falls
5°F below the HSLLS.

2. Limit the capacity to 50 percent (one compressor per circuit), initiate an
auto reset diagnostic until the LST falls 5°F below the HSLLS.

12 CSRA-SVX02A-EN

General
Information

3. Turn “Off” and lockout all of the compressors and initiate a manual reset
diagnostic.

Loss-of-Flow (Solution) Protection (Standard)

The factory installed solution flow switch is wired to the CGM. If it opens for
more than 6 continuous seconds when the pump is requested to be “On”, an
auto reset diagnostic will be initiated. If no compressors are operating, they
will be inhibited from starting. Any time the compressors are operating, they
will be turned “Off”. Once flow has been reestablished, full unit operation will
be allowed.

In addition, a low pressure cutout and the entering (EST) and leaving
solution temperature (LST) sensors provide loss of flow protection for the
unit.

When there is a cooling demand, the CGM compares the EST to the LST. If
the EST is 2°F or more below the LST, the chiller is stopped and a manually
reset diagnostic is initiated. This input has priority over all other commands
received by the CGM.

Low Ambient Start (Standard)

Is accomplished by utilizing an additional low pressure cutout (LPC) that is
ignored at start-up for varying periods of time, depending on the prevailing
ambient temperature. The relationship between this variable time period and
the ambient temperature is linear from a maximum of 5 minutes at 0°F to a
minimum of 30 seconds at 65°F. The bypass time is initiated each time a
compressor is started on a refrigerant circuit when no other compressor on
that circuit is operating. No additional compressors will be allowed to operate
within that circuit until the bypass time has expired.

Chiller Solution Pump Output Relay (Standard)

A Solution Pump binary output (Form C) relay is located on the CGM which
may be used to control the chiller solution pump.

If the Chiller Solution Pump Mode, at the Human Interface Module, is set to
“On”, the Solution Pump will run continuously.

If the Chiller Solution Pump Mode, at the Human Interface Module, is set to
Auto, the Solution Pump will be turned “Off”:

1. when the unit is stopped (Unit Stop or External Auto/Stop)

2. during the unit's Power On Delay Time

3. when the primary control states are:

Ice Rebuild Delay
Ice Building Complete

A Solution Pump “Off Delay” Time may be programmed to allow the Solution
Pump to remain “On” after a shut down request has been received. The
delay is adjustable between 0.5 minutes and 10 minutes after an “Off” state
is initiated. The Solution Pump will always run for this delay time when

CSRA-SVX02A-EN 13

General
Information

turning off except during an Emergency Stop condition. If an Emergency
Stop is initiated, the Solution Pump is immediately turned “Off” (relay de­energized).

Low Ambient Pump Control (Standard)

A Low Ambient Pump “On” Control function (LAPC) allows the pump to run
continuously if the outside ambient temperature falls below a programmable
Low Ambient Pump “On” Temperature (LAPT) Setpoint or if an outside
ambient temperature input failure occurs. An Auto Reset Diagnostic will be
issued and remain as long as the condition exists.

This function will be disabled when an Emergency Stop request is initiated.

During service test operation, if a low ambient condition exists when the
operator attempts to turn the pump “Off”, a message will be displayed on the
Human Interface Module advising that the pump cannot be turned off due to
the low ambient condition.

Emergency Stop (Optional)

Is accomplished when a customer provided, field installed binary input
device is connected to the CGM. The unit will immediately shut down when
the contacts are opened. Emergency Stop is a top priority command that will
override all other commands received by the UCM. A manual reset
diagnostic will occur and an indication showing that the unit is shut down due
to Emergency Stop will be displayed at the Human Interface Module.

External Auto/Stop (Optional)

The unit can be Stopped and Started by a remote customer provided field
installed binary input device (such as a time clock) connected to the CGM.
When the input is opened (Stop), the unit will stage the compressors and the
solution pump “Off” in a normal manner and display “Off due to external
stop” at the unit Human Interface. When the input is closed (Start), the unit
will start and run normally.

The External Auto/Stop input operates in the same manner as the STOP/
AUTO keys on the unit mounted Human Interface or the Remote Human
Interface (RHI). However, the Stop key at the unit mounted Human Interface
has priority over both the remote External Auto/Stop and the Remote Human
Interface Auto/Stop.

Note: If the STOP key is pressed at the unit mounted Human Interface, no
remote AUTO (Start) key will start the unit until the AUTO key is pressed at
the unit mounted Human Interface.

A start (AUTO) command is allowed only if no overriding diagnostics or
higher priority function is present.

14 CSRA-SVX02A-EN

Control Panel

Condenser Fans

Typical Lifting Holes (4)

Pump Circuit Breaker/Control
Panel Enclosure

Tow Bar

General
Information

Figure 2 — Unit Component “Layout” and “Ship with” Locations (60
Ton Unit Illustrated)

Forklift
Tube
Slots

Water Inlet

Unit Inspection

As soon as the unit arrives at the job site

[ ] Verify that the nameplate data matches the data on the sales order and bill
of lading (including electrical data).

[ ] Verify that the power supply complies with the unit nameplate
specifications.

[ ] Visually inspect the exterior of the unit, including the roof, for signs of
shipping damage.

[ ] Check for material shortages. Refer to Figure 2, “Component Layout and
Ship with Location”.

If the job site inspection of the unit reveals damage or material shortages, file
a claim with the carrier immediately. Specify the type and extent of the
damage on the “bill of lading” before signing.

[ ] Visually inspect the internal components for shipping damage as soon as
possible after delivery and before it is stored. Do not walk on the sheet metal
base pans.

Water Outlet

CSRA-SVX02A-EN 15

Installation

WARNING

No Step Surface!

Do not w alk on the sheet metal drain pan. W alking on the drain pan
could cause the supporting metal to collapse. Failure of the drain pan
could result in death or serious injury.

Bridging between the unit's main supports may consist of multiple 2 by 12
boards or sheet metal grating.

[ ] If concealed damage is discovered, notify the carrier's terminal of damage
immediately by phone and by mail. Concealed damage must be reported
within 15 days.

Request an immediate joint inspection of the damage by the carrier and the
consignee. Do not remove damaged material from the receiving location.
Take photos of the damage, if possible. The owner must provide reasonable
evidence that the damage did not occur after delivery.

[ ] Notify the appropriate Trane office before installing or repairing a
damaged unit.

Unit Clearances

Figure 3 illustrates the minimum operating and service clearances for either
a single, multiple, or pit application. These clearances are the minimum
distances necessary to assure adequate serviceability, cataloged unit
capacity, and peak operating efficiency.

Providing less than the recommended clearances may result in condenser
coil starvation or recirculation of hot condenser air.

Locate the unit as close to the applicable system support equipment as
possible to minimize refrigerant piping lengths.

Unit Dimensions & Weight Information

• Overall unit dimensional data for each unit is illustrated in Figure 4.

• A Center-of-Gravity illustration and the dimensional data is shown in
Figure 5.

• Table 1 lists the typical unit operating and point loading weights.

Foundation

If the unit is installed at ground level, elevate it above the snow line. Provide
concrete footings at each support location or a slab foundation for support.
Refer to Table 1 for the unit operating and point loading weights when
constructing the footing foundation.

For rooftop applications, ensure the roof is strong enough to support the
unit. Refer to Table 1 for the unit operating weights.

16 CSRA-SVX02A-EN

Installation

Anchor the unit to the roof with hold-down bolts or isolators. Follow the
instructions under “Unit Isolation” for proper isolator placement and
installation.

Check with a roofing contractor for proper waterproofing procedures.

Figure 3 — Typical Installation Clearances for Single, Multiple or Pit
Applications

CSRA-SVX02A-EN 17

Installation

Figure 4a — C25 Ton Unit Dimensional Data & Recommended
Clearances

18 CSRA-SVX02A-EN

Installation

Figure 4b — C40 Ton Unit Dimensional Data & Recommended
Clearances

CSRA-SVX02A-EN 19

Installation

Figure 4c — C60 Ton Unit Dimensional Data & Recommended
Clearances

20 CSRA-SVX02A-EN

Installation

Table 1 — Typical Unit Weights and Point Loading Data

Unit Weights
Model No. Tons Shipping Operational Dimensioned from Pump End

Weight (lbs) Weight (lbs) X
CSRA010FAF0 10 3800 3820 57
CSRA015FAF0 15 4030 4050 74
CSRA025FAF0 25 6050 6150 83.0
CSRA040FAF0 40 8250 8370 79.0
CSRA060FAF0 60 9300 9615 96.0

Notes:

1. Mounting locations correlate with those shown in point loading illustration.

2. Operating weight includes refrigerant, oil, and water.

3. Shipping weight includes refrigerant and oil charges.

Figure 5 — Rigging and Center-of-Gravity Data

CSRA-SVX02A-EN 21

Installation

WARNING

Heavy Objects!

Do not use cables (chains or slings) except as shown. Each of the cables
(chains or slings) used to lift the unit must be capable of supporting the
entire w eight of the unit. Lifting cables (chains or slings) may not be of
the same length. Adjust as necessary for even unit lift. Other lifting
arrangements may cause equipment or property-only damage. Failure to
properly lift unit may result in death or serious injury. See details below.

Rigging

A Rigging illustration and Center-of-Gravity dimensional data table is shown
in Figure 5 and Table 1. Refer to the typical unit operating weights table
before proceeding.

1. Rig the condensing unit as shown in Figure 5. Attach adequate strength
lifting slings to all four lifting brackets on the lifting frame. Do not use
cables, chains, or slings except as shown.

2. Install spreader bars, as shown in Figure 5, to protect the unit and to facil­itate a uniform lift. The minimum distance between the lifting hook and
the top of the unit should be 7 feet.

3. Test-lift the unit to ensure it is properly rigged and balanced, make any
necessary rigging adjustments.

4. Lift the unit and position it into place.

Leveling the Unit

Use the unit base rail as a reference. Level the unit to within 1/4 inch over its
entire length. Use shims when required.

Shipping Fasteners

Compressor Shipping Hardware

Figure 6 illustrates the location of each tie down bolt and rubber isolator bolt
for the compressor assembly in each circuit. Refer to the illustration and the
following discussion to locate and remove the fasteners.

Two Manifolded Compressors

Each manifolded compressor assembly is rigidly bolted to a mounting rail
assembly. The rail assembly sets on four (4) rubber isolators. The assembly
is held in place by two shipping braces that secure each compressor
assembly rail to the unit's base rail. To remove the shipping hardware, follow
the procedures below:

1. Remove the four anchor bolts (2 front and 2 rear), used to secure the
shipping brace to the unit's base rail.

2. Remove the three self-tapping screws that secure each shipping brace to
the compressor mounting rails.

3. Remove and discard the two 30-1/2” long shipping braces for each
assembly.

4. Do not remove the shipping plate located on top of the compressors.

22 CSRA-SVX02A-EN

Installation

5. Ensure that the compressor rail assembly is free to move on the rubber
isolators.

Figure 6 — Removing C25 through C60 Scroll Compressor Shipping
Hardware Installation

General Unit Requirements

The checklist listed below is a summary of the steps required to successfully
install a commercial air cooled unit. This checklist is intended to acquaint the
installing personnel with what is required in the installation process. It does
not replace the detailed instruction called out in the applicable sections of
this manual.

[ ] Verify that the power supply complies with the unit nameplate
specifications.

[ ] Check the unit for shipping damage and material shortage; file a freight
claim and notify Trane office.

[ ] Verify that the installation location of the unit will provide the required
clearance for proper operation.

Chilled Water Piping Requirements

[ ] Flushing the chilled solution piping system, if applicable.

CAUTION
Evaporator Damage!

If using an acidic, commercial flushing solution, flush all chilled solution
piping before making the final connection to the EVP chiller barrel.
Failure to do so may result in evaporator damage.

[ ] Install heat tape and insulation, if necessary, to protect any exposed
solution piping from external freezing conditions.

CSRA-SVX02A-EN 23

Installation

Main Electrical Power Requirements

[ ] Verify the power supply meets the required power requirements of the
system.

[ ] Install power wiring in accordance with all applicable codes.

[ ] Install and connect properly sized power supply wiring, with over current
protection, to the main circuit breaker (ICB1).

[ ] Install and connect properly sized power supply wiring, with over current
protection, to the proper termination point in the air handling unit (If
applicable).

[ ] Install and connect properly sized power supply wiring, with over current
protection, to the proper termination point for the chilled solution pump
(when choosing not to use pump supplied with chiller).

[ ] Install proper grounding wires to an earth ground.

Chilled Water Piping

Evaporator water inlet and outlet types, sizes and locations are shown in
Figure 4. Refer to the operating GPM parameters listed in Table 8a-c when
determining flow and piping requirements.

Air Vents

A vent port is located on top of the chiller near the return end. Additional
vents must be installed at high points in the piping system to facilitate air
purging during the filling process.

Water Pressure Gauges

A water pressure gauge is installed near the inlet side of the chiller barrel
with appropriate piping to measure the entering and leaving solution
pressure.

CAUTION
Evaporator Damage!

Do not exceed 150 psig evaporator pressure. Failure to do so may cause
evaporator damage.

24 CSRA-SVX02A-EN

Installation

Water Shutoff Valves

Shutoff valves are provided in the “Supply” and “Return” pipe near the chiller
so the gauge(s), thermostats, sensors, strainer, etc., can be isolated during
service.

Pipe Unions and Connectors

Pipe unions and Victaulic connectors are used to simplify disassembly for
system service.

Thermometers

Temperature gauges are used in the lines to monitor the evaporator entering
and leaving water temperatures.

Balancing Valves

A balancing cock (valve) is installed in the leaving water line. It will be used
to establish a balanced flow.

Note: Both the entering and leaving water lines have shutoff valves installed
to isolate the evaporator for service.

Strainer

A pipe strainer is installed in the water return line (inlet piping to chiller) to
protect the components from entrapped debris.

Chiller Drain

The chiller drain is piped to the outside of the chiller casing with a ball shutoff
valve to facilitate evaporator draining during service or shutdown
procedures.

Chiller Flow Switch

A flow switch, illustrated in Figure 7, is installed to prevent or stop the
compressor operation if the water flow drops off drastically. Refer to unit
schematics for the flow switch electrical interlock connections.

Figure 7 — Optional Flow Switch Illustration

CSRA-SVX02A-EN 25

Installation

Final Water Piping Connections

1. All water piping to the system should be flushed thoroughly before mak­ing the final connections.

CAUTION
Pump Damage!

If using an acidic commercial flushing solution, construct a temporary
bypass around the pump and unit. Failure to do so may lead to
equipment damage.

2. Connect the water pipe to the EVP chiller.

3. Ensure the drain shutoff valve is closed.

4. While filling the chiller system with solution, vent the air from the system
at the highest points.

CAUTION
Proper Water Treatment!

The use of untreated or improperly treated w ater in an Air-Cooled Cold
Generator may result in scaling, erosion, corrosion, algae or slime. It is
recommended that the services of a qualified w ater treatment specialist
be engaged to determine w hat w ater treatment, if any, is required.
Trane assumes no responsibility for equipment failures w hich result from
untreated or improperly treated w ater, or saline or brackish w ater.

Evaporator Water Piping

The unit's water connection sizes and locations are shown in Figure 4.

CAUTION
Component Damage!

Evaporator pressure should not exceed 1 50 psig (i.e., maximum working
pressure). Failure to do so may lead to equipment damage.

CAUTION
Pump Damage!

Do not reverse system w ater piping connections to the unit or pump.
Failure to follow these instructions may result in pump or unit damage.

Water entering the evaporator is pre-piped to the discharge of the pump. If
the pump is not required, open bypass valve and close inlet and discharge
valves on pump. “Water Inlet” to the evaporator must enter on inlet
connection to pump. Leaving water must exit the evaporator through the
designated “Water Outlet” connection.

26 CSRA-SVX02A-EN

Installation

Flexible Hose and Hard Pipe Installation

General

Use the procedure described below to ensure the proper installation of
flexible hose provided as part of a ChillerSource rental. It is critical that this
procedure is followed to minimize premature or catastrophic failure of this
hose.

CAUTION
Hose Damage!

Hose must never be pressurized over 1 5 0 psi. If higher pressures are
required, “hard” suction pipe must be utilized. Failure to do so may lead
to hose damage.

CAUTION
Hose Damage!

Hose must alw ays be used in pressurized application. If a negative
pressure application is required, “hard” suction pipe must be utilized.
Failure to do so may lead to hose collapse and total system failure.

Flexible Hose Guidelines

WARNING

Hose Failure

Failure to comply w ith installation instructions that follow may result in
death or serious injury or equipment damage.

• Do not support the hose ONLY by its couplings; support over half of
the hose's length by ground or other supporting surface otherwise
coupling clamps may fail.

• Do not run hose vertically more than 7 feet otherwise coupling clamps
may fail.

• Do not cut hose to “custom” fit pieces-this will affect the integrity of
the hose.

• Bleed all air from the system prior to pressurizing hose to avoid cou­plings separating from the hose.

• Install elbows for a smooth hose transition on all vertical hose installa­tions, see Figure 10 (Correct Vertical Hose Installation)

• Never pressurize hose above 150 psi.

CSRA-SVX02A-EN 27

Installation

Dixon Coupling

• The Dixon coupling (See Figure 7), bolts are to be torqued prior to
charging the hose with water to 40 ft-lbs. DO NOT EXCEED 40 ft-lbs.
(The torque must be applied evenly between the bolts to ensure a
consistent gap on each side of the coupling. Some pinching of the
excess hose in the gap area is considered normal and will not create
a leak or premature failure.)

• Continually monitor and retighten, if necessary, on monthly inspec­tion intervals.

Figure 7 — Dixon Coupling

The following figures illustrate the correct and incorrect methods for
installing hose in a horizontal hookup application.

Figure 8 — Correct Horizontal Hose Installation

Correct horizontal hose installation shows a correct hose installation. In this
configuration either a 45° or 90° elbow can be installed. This elbow prevents
stretching and crimping of the hose at the hose coupling connection. This
elbow also directs the hose to the ground at an appropriate angle to
minimize the crimping of the hose at the ground or supporting surfaces.

28 CSRA-SVX02A-EN

Installation

Figure 9 — (Incorrect Horizontal Hose Installation)

Incorrect horizontal hose installation shows an incorrect hose installation.
Elbows are not installed. This causes the top of the hose to be in tension,
which stretches the hose out of the coupling; and the bottom of the hose to
be in compression, which causes it to crimp. It also causes the hose to crimp
at the ground.

The following figures illustrate the correct and incorrect methods for installing
hose in a vertical hookup application.

Figure 10— Correct Vertical Hose Installation

Correct vertical hose installation shows a correct vertical hose installation. In
this configuration, the hose is installed with an elevation less than 7 feet off
the ground. A 45° elbow is installed to reduce the stress in the hose coupling
connection. This elbow also directs the hose to the ground at an appropriate
angle to minimize the crimping of the hose at the ground or supporting
surface.

CSRA-SVX02A-EN 29

Installation

Figure 11 — Incorrect Vertical Hose Installation

Incorrect vertical hose installation shows an incorrect hose installation. In
this configuration the hose is installed without an elbow and with an
elevation greater than 7 feet off the ground. This creates excessive stress at
the hose coupling connection, causing the hose to stretch and separate from
the coupling. It also causes the hose to crimp at the ground.

The following figures illustrate the correct and incorrect methods for
installing hose in a horizontal and vertical combination application.

Figure 12 — Correct Horizontal/Vertical Installation

Correct horizontal/vertical installation shows a correct horizontal/vertical
hose installation. In this configuration, correct installation techniques
followed are:

• the hose is installed with elbows at both connection ends

• the vertical run of hose is less than 7 feet

• the hose is adequately supported by more than half its total length on
the ground

These items minimize the stretching and separation at the hose-coupling
interface and also the crimping of the hose at the ground.

30 CSRA-SVX02A-EN

Installation

Figure 13 — Incorrect Horizontal/Vertical Installation

Incorrect horizontal/vertical installation shows an incorrect horizontal/vertical
hose installation. In this configuration, a number of improper installation
techniques can be noted:

• elbows are not installed

• the hose is completely supported by the couplings

• the vertical run of hose is greater than 7 feet

• the hose is not adequately supported by the ground

Figure 14 — Correct Unsupported Horizontal Installation

Correct unsupported horizontal installation illustrates a correct horizontal
hose installation where there is a section of unsupported hose. The length of
unsupported hose should be less than 7 feet. Also, the hose must be
adequately supported by having more than half its total length on the ground.

CSRA-SVX02A-EN 31

Installation

Hard Pipe Guidelines

Certain installations may require the use of hard pipe (steel or PVC). Hard
pipe is typically recommended for (1) INDOOR INSTALLATIONS, (2) semi­permanent installations (three months or more) and/or (3) installations with
space limitations.

When installing hard pipe:

• construct and install the piping according to local and national codes

• isolate and support the piping as required to prevent stress on the
unit and vibration to building piping

If there are any questions regarding how to install water piping, contact a
ChillerSource Technical Service Advisor, Charlotte, NC (800-755-5115).

Material Disposition

In the event the hose fails or leaks, call the ChillerSource Technical Service
Advisor in Charlotte, NC (800-755-5115); tag the hose “BAD” and place it
back in the shipping box.

Exceptions

The ChillerSource Technical Service Advisor, Charlotte, NC, must authorize
any exceptions to the guidelines established in this bulletin in writing.

Freeze Protection from Ambient Conditions

Use the procedure described below to ensure that the chilled water system
is adequately protected from freeze-up in applications where the unit
remains operational at subfreezing ambient temperatures and against ice
formation at the lowest expected operating temperatures by adding a non­freezing, low-temperature, heat-transfer fluid to the chilled water.

For evaporator water capacities, refer to the “System Start-Up” section. For
the use and testing of the antifreeze solution, follow the manufacturer's
recommendations.

Note: Use of an ethylene glycol-type antifreeze reduces unit cooling
capacity; this condition must be accounted for during total system design.
Also, the low pressure control may need to be changed. Contact the local
Trane ChillerSource representative.

For all 60 Hz units, heat tape is factory-installed on the unit evaporator and
all internal water piping.

This heat tape will protect the evaporator and internal piping from freezing
due to low ambient temperatures down to -20°F. Heat tape power draw for
60 Hz units is 210 Watts on 25-30 Ton units, and 420 Watts on 40 through
60 Ton units.

32 CSRA-SVX02A-EN

Installation

Install an appropriately sized fused disconnect switch for field installed heat
tape when applying it to all exposed piping. A shore power 115V plug is
provided for factory installed heat tape. Be sure to use heat tape that is
recommended for low-temperature applications, it should be thermostatic
controlled and dissipate 7 watts per linear foot. A field installed thermostat
must be installed if the heat tape does not include a thermostat.

To install the heat tape properly, follow the instructions provided by the heat
tape manufacturer. If no instructions are provided, use the recommendations
outlined below:

1. Wrap the heat tape around the pipe or apply it straight along the pipe, as
necessary, to provide the required protection. Refer to Figure 15 and
Tables 2A and 2B.

2. Use friction tape to secure the heat tape to the solution pipe.

3. Place the thermostat parallel to the water pipe and tape it tightly in place
at both ends. Be sure to install the thermostat on the most exposed (i.e.,
coldest) portion of the pipe.

4. Wrap the pipe with an insulation material and cover it with a weatherproof
tape (if additional protection is required). On vertical pipe runs, start the
wrap at the bottom and work up as shown in Figure 15. Be sure to over­lap the tape so that it will shed moisture.

Note: To prevent heat tape failure, frozen pipes, and other unit damage, do
not install insulation under the weatherproof wrap if a non-thermostatic
controlled heat tape is used.

CSRA-SVX02A-EN 33

Installation

Figure 15 — Typical Insulated, Spiralled Heat Tape Installation

Table 2A — Non-Insulated, Non-Thermostatically Controlled Heat Tape
with Outer Wrap

Application

Technique “Straight”

Heat Tape Req. per Linear

Ft. of Pipe

Protection Down to (°F) 6° 11° 15° 20° 22°

“Spiralled”

Heat Tape Req. per Linear

Ft. of Pipe

Protection Down to (°F) -27° -23° -20° -17° -15°

Note: Spiralled applications are twisted around pipe 3 turns per linear foot of
pipe.

2” 2-1/2” 3” 4” 5”

12” 12” 12” 12” 12”

28” 31” 35” 47” 54”

Pipe Size

34 CSRA-SVX02A-EN

Installation

Table 2B — Insulated, Non-Thermostatically Controlled Heat Tape with
Outer Wrap

Application

Technique “Straight”

Heat Tape Req. per Linear

Ft. of Pipe

Protection Down to (°F) -6° 0° 3° 12° 16°

“Spiralled”

Heat Tape Req. per Linear

Ft. of Pipe

Protection Down to (°F) -55° -50° -45° -40° -1°

Note: Spiralled applications are twisted around pipe 3 turns per linear foot of
pipe.

2” 2-1/2” 3” 4” 5”

12” 12” 12” 12” 12”

26” 31” 35” 47” 54”

Pipe Size

Electrical Cable

Technical Data

Conductor Size: 2/0 AWG

Ampacity: 300 Amps per conductor*

Construction: Rope stranded copper conductor, colored-coded (blue, red,

green and black) connectors on each end. Insulation is
composed of water, acid, ozone and chemical resistant
thermoplastic rubber compound.

Temperature Rating (°F): -49 to 194

Weight (Lbs./100 Ft.): 64

Conductor Nominal OD (in.): 0.8200

Cable Rating: UL Rated at 2000 Volts, C(UL) 600 volts for continuous use.

*The values listed above are based upon ambient temperature @ 86 °F,
where the individual conductor is not installed in raceways or buried
(Reference NEC Code, Table 310-16, 1999 Edition).

CSRA-SVX02A-EN 35

Installation

*Temperature Correction Factors

Ambient Temp °F

70 - 77 1.04

78 - 86 1.00

87 - 95 0.96

96 - 104 0.91

105 - 113 0.87

114 - 122 0.82

Electrical Cable Box

The electrical cable is contained in a lightweight plastic box, approximately
four feet long and four feet wide. The contents are as follows: Four (4) 100'
sections of 2/0 awg cable and eight (8) 15' pig-tails.

Figure 16 — Electrical Cable Box

Factor

Cam-lok Connectors

Each cable is supplied with a male cam-lok on one end and a female cam­lok on the other. The cam-lok connectors provide quick, easy one-twist
connections. The picture to the right depicts a typical connection. *For non
cam-lok connections four male pig-tails and four female pig-tails are
provided in a standard electrical cable box (see Pig-Tail Connectors).

36 CSRA-SVX02A-EN

Installation

Figure 17 — Cam-lok Connectors

Pig-Tail Connectors

Each cable box has four male pig-tails and four female pig-tails for non cam­lok connections. Each male pig-tail has a male cam-lok on one end and a
barrel lug on the other. Each female pig-tail has a female cam-lok on one
and a barrel lug. The barrel lug end allows for connection into a power
distribution panel or non cam-lok equipment. The pig-tail can then be
connected to the standard cam-lok cable, see schematic below.

Pig-Tail/Cam-Lok Connection Schematic

Lug

M F M F Lug

CSRA-SVX02A-EN 37

Installation

Figure 18 — Pig-tail Connectors

Field Installed Power Wiring

An overall dimensional layout for the field installed wiring entrance into the
unit is illustrated in Figure 4. To insure that the unit's supply power wiring is
properly sized and installed, follow the guidelines outlined below.

Note: All field installed wiring must conform to NEC guidelines as well as
State and Local codes.

Verify that the power supply available is compatible with the unit's nameplate
ratings. The available supply power must be within 10% of the rated voltage
stamped on the nameplate. Use only copper conductors to connect the 3­phase power supply to the unit.

CAUTION
Use Copper Conductors Only!

Unit terminals are not designed to accept other types of conductors.
Failure to use copper conductors may result in equipment damage.

Circuit Breaker External Handle
(Factory Mounted Option)

Units are provided with an externally mounted circuit breaker handle. This
allows the operator to disconnect power from the unit without having to open
the control panel door. The handle locations and its three positions are
shown below;

“ON” - Indicates that the circuit breaker is closed, allowing the main
power supply to be applied at the unit.

“OFF” - Indicates that the circuit breaker is open, interrupting the
main power supply to the unit controls.

“OPEN COVER/RESET” - Turning the handle to this position releases
the handle from the circuit breaker, allowing the control panel door to be
opened.

38 CSRA-SVX02A-EN

Installation

WARNING

Hazardous Voltage!

Disconnect all electric pow er, including remote disconnects before
servicing. Follow proper lockout/tagout procedures to ensure the pow er
can not be inadvertently energized. Failure to disconnect power before
servicing could result in death or serious injury.

Once the door has been opened, it can be closed with the handle in any one
of the three positions outlined above, provided it matches the circuit breaker
position.

An overall layout of the field required power wiring is illustrated in Figure 19.
These diagrams are representative of standard applications and are for
general reference only. Always refer to the wiring diagram that shipped with
the unit for specific electrical schematic and connection information.

Main Unit Power Wiring

Table 3 lists the field connection wire ranges for both the cam-type
connector and lug-type connector in the main power supply box The unit
electrical data is listed in Table 4. The electrical service must be protected
from over current and short circuit conditions in accordance with NEC
requirements. Protection devices must be sized according to the electrical
data on the nameplate. Refer to the “Power Wire Sizing & Protection Device
Equations”, for determining;

A. the appropriate electrical service wire size based on “Minimum Circuit Am-

pacity” (MCA),

B. the “Maximum Over current Protection” (MOP) device.
C. the “Recommended Dual Element fuse size” (RDE).

1. A field supplied disconnect switch must be installed at or near the unit in
accordance with the National Electrical Code (NEC latest edition). Refer
to the “Power Wire Sizing & Protection Device Equations” (DSS calcula­tion), for determining the correct size.

2. Complete the unit's power wiring connections onto either the factory sup­plied cam-type receptacle, or the factory mounted lug-type connector
inside the power supply box. There are also 3/8” holes provided for field
supplied wire terminals. Refer to the customer connection diagram that
shipped with the unit for specific termination points.

3. Provide proper grounding for the unit in accordance with local and
national codes

CSRA-SVX02A-EN 39

Installation

Figure 19 — Typical Field Installed Power Wiring for Field Installed
Pump

Refer to the Wiring Diagram Notes at the end of this Section

40 CSRA-SVX02A-EN

Installation

Table 3 — Customer Connection Wire Range

Power Wire Sizing and Protection Device Equations

To correctly size the main power wiring for the unit, use the appropriate
calculation(s) listed below. Read the load definitions that follow and use
Calculation #1 for determining the MCA (Minimum Circuit Ampacity), MOP
(Maximum Over current Protection), and RDE (Recommended Dual Element
fuse size) for each unit. Use Calculation #2 to determine the DSS
(Disconnect Switch Size) for each unit.

Load Definitions: LOAD 1 = CURRENT OF THE LARGEST MOTOR

(COMPRESSOR OR FAN MOTOR)

LOAD 2 = SUM OF THE CURRENTS OF ALL
REMAINING MOTORS

LOAD 4 = CONTROL POWER TRANSFORMER
= AND ANY OTHER LOAD RATED AT 1
AMP OR MORE

Calculation #1
(MCA, MOP, and RDE)

MCA = (1.25 x LOAD 1) + LOAD 2 + LOAD 4

MOP = (2.25 x LOAD 1) + LOAD 2 + LOAD 4

Select a fuse rating equal to the MOP value. If the MOP value does not equal
a standard fuse size as listed in NEC 240-6, select the next lower standard
fuse rating.

Note: If selected MOP is less than the MCA, then select the lowest standard
maximum fuse size which is equal to or larger than the MCA, provided the
selected fuse size does not exceed 800 amps.

CSRA-SVX02A-EN 41

Installation

CGAF25

CGAF40

CGAF60

561

23

,

4

RDE = (1.5 x LOAD 1) + LOAD 2 + LOAD 4

Select a fuse rating equal to the RDE value. If the RDE value does not equal
a standard fuse size as listed in NEC 240 - 6 select the next higher standard
fuse rating.

Note: If the selected RDE is greater than the selected MOP value, then
select the RDE value to equal the MOP value.

Calculation #2
Disconnect Switch Sizing (DSS)

DSS = 1.15 X (LOAD 1 + LOAD 2 + LOAD 4)

Table 4 — Unit Electrical Data

Unit
Size

Compressor Motor (Each)

Rated

Voltage

460/60/3 61 80 2 17.1/25.4 117/178 3 1.8 0.9 1 6.5 5

460/60/3 92 90 4 17.2 117 4 1.8 0.9 1 12.0 10

460/60/3 131 125 4 25.4 178 6 1.8 0.9 1 12.0 10

Min.
Ckt.

Amp.

Max. Fuse

Size

Qty

RLA

LRA Qty FLA Kw Qty FLA HP

Cond. Fan Motors

(Each)

Pump

Notes:

1. Minimum Circuit Ampacity is 125% of the largest compressor RLA plus 100% of the other compressor RLA
plus the sum of the condenser fan FLA plus any other load rated at 1 Amp or more.

2. Maximum Fuse Size is 225% of the largest RLA plus 100% of the other compressor RLA plus the sum of
the condenser fan FLA plus any other load rated at 1 Amp or more.

3. Recommended Dual Element Fuse Size is 150% of the largest compressor RLA plus 100% of the other
compressor RLA plus the sum of the condenser fan FLA plus any other load rated at 1 Amp or more.

4. RLA is rated in accordance with UL Standard 465. Local codes may take precedence.

5. All units are across-the-line starting. Compressors will never start simultaneously.

6. (60 Hz units) One field provided 115/60/1, 15 amp power supply is required to operate the evaporator heat
tape.
(50 Hz unit) One field provided 240/50/1, 5 amp power supply is required to operate the evaporator heat tape.

Field Installed Control Wiring

Before installing any connecting wiring, refer to Figure 4 for the electrical
access locations provided on the unit. Install appropriately sized control
wiring for the 115 volt electrical components as required by the application.

WARNING

Hazardous Voltage!

Disconnect all electric pow er, including remote disconnects before
servicing. Follow proper lockout/tagout procedures to ensure the pow er
can not be inadvertently energized. Failure to disconnect power before
servicing could result in death or serious injury.

42 CSRA-SVX02A-EN

Installation

Since the unit-mounted 115V control power transformer (1T1) and the 24V
control power transformers (1T2, 1T3, 1T4) are provided on all units, it is not
necessary to run a separate 115 volt control circuit power source to the unit.

A separate field provided 15 Amp maximum 115V 60 Hz power source is
required when the unit is equipped with field supplied heat tape. Refer to the
wiring diagrams that shipped with the unit for proper connections. The
factory supplied evaporator heat tape already is conveniently wired and can
be energized by connecting to the shore power receptacle on the unit.

Note: All field wiring must conform to NEC guidelines as well as state and
local codes.

Controls using 24 VAC

Before installing any connecting wiring, refer to Figure 4 for the electrical
access locations provided on the unit and Table 5 for AC conductor sizing
guidelines, and;

A. Use copper conductors unless otherwise specified.

B. Ensure that the AC control wiring between the controls and the unit's ter-

mination point does not exceed three (3) ohms/conductor for the length of
the run.

Note: Resistance in excess of 3 ohms per conductor may cause component
failure due to insufficient AC voltage supply.

C. Be sure to check all loads and conductors for grounds, shorts, and miswir-

ing.

D. Do not run the AC low voltage wiring in the same conduit with the high volt-

age power wiring.

Install appropriately sized 24 volt AC/DC control wiring for the electrical
components as required by the application.

These components may include:

• Remote Running/Alarm Indicator

• External Auto/Stop

• Flow Control Interlock

Table 5 — AC Conductors

Distance from

Unit to Control

000 - 460 feet 18 gauge

461 - 732 feet 16 gauge

733 - 1000 feet 14 gauge

Recommended

Wire Size

CSRA-SVX02A-EN 43

Installation

Remote Running/Alarm Indicator (Optional)

If the remote run indication and alarm contacts are used, a 24 VAC control
circuit must be provided between the Remote Running/Alarm Indicator panel
and the appropriate terminals located at the UCM. Maximum contact rating
@ 24 VAC is 10 Amp in-rush and 3.2 Amp sealed. Refer to the “Field Wiring”
diagrams illustrated in Figure 20A. Provide a proper remote panel ground
connection.

External Auto/Stop (Optional)

If the unit utilizes an optional remote Auto/Stop function, the installer must
provide control wiring from the remote pump relay contacts (5S67) to the
appropriate terminals on 1TB4 terminal board.

When this set of contacts opens, the UCM reads it as a command to stop
chiller operation and begin the pump down cycle (if enabled).

Circuit requirements are 2-wire, 24 VDC; w/maximum contact rating 12 mA.
Refer to the field wiring diagram illustrated in Figure 20A for the termination
points.

Flow Control Interlock (6S1)

The flow switch is a binary output device and is wired within the interlock
circuit if a chilled water flow interlock diagnostic is desired for the system.
Before installing the control wiring, refer to Figure 4 for the electrical access
into the control panel. Refer to the field connection diagram for the specific
connection points.

Provide a proper ground for all control circuitry at the ground connection
screws provided within the unit's control panel.

Controls using DC Analog Input/Outputs
(Standard Low Voltage Multiconductor Wire)

Before installing any connecting wiring between the unit and components
utilizing a DC analog input\output signal, refer to Figure 4 for the electrical
access locations provided on the unit.

A. Table 6 lists the conductor sizing guidelines that must be followed when

interconnecting the DC Installation binary output devices and the system
components utilizing a DC analog input\output signal to the unit.

Note: Resistance in excess of 2.5 ohms per conductor can cause deviations
in the accuracy of the controls.

B. Ensure that the wiring between the binary and analog controls and the

unit's termination point does not exceed two and a half (2.5) ohms/conduc­tor for the length of the run.

C. Do not run the electrical wires transporting DC signals in or around conduit

housing high voltage wires.

44 CSRA-SVX02A-EN

Installation

Table 6 — DC Conductors

Distance from

Unit to Control

000 - 499 feet 16 gauge

500 - 1000 feet 14 gauge

Recommended

Wire Size

Controls using DC Communication Links

Before installing any connecting wiring between the unit and components
utilizing a DC communication link, refer to the connection diagram that
shipped with the unit for the electrical access and connection locations
provided on the unit.

A. Wiring for the components utilizing a DC communication link must be

shielded cable (Belden 8760 or equivalent). Ground the shield at one end
only.

B. Table 6 lists the conductor sizing guidelines that must be followed when in-

terconnecting a communication link to the unit.
C. Communication link must not exceed 5,000 feet maximum for each link.
D. Communication link must not pass between buildings.
E. Do not run the electrical wires transporting DC signals in or around conduit

housing AC voltage wires.

Table 7 — Maximum Communications Wiring Length

Maximum

Communication

Link Wiring Length

1,000 feet Up to 60 PF/FT

2,000 feet Up to 50 PF/FT

3,000 feet Up to 40 PF/FT

4,000 feet Up to 30 PF/FT

5,000 feet Up to 25 PF/FT

PF/FT = Picofarads/foot

CSRA-SVX02A-EN 45

Maximum

Capacitance

Between

Conductors

Installation

ICS™ Communication Link

This option allows the unit control module (UCM) in the unit to exchange
information (i.e., operating setpoints and AUTO/STOP commands) with a
higher level control device, such as a Tracer. Twisted-pair conductors
establish the bi-directional communications link between the unit's control
module and Tracer.

1. Refer to the Tracer installation literature to determine proper communica­tion link termination connections at the Tracer unit. Multiple UCM's on the
communication link can be connected in a “daisy chain” configuration.

2. Connect the shield of the communication link wiring to the designated
shield terminal at the Tracer 100.

3. Connect the shielded, twisted pair leads from the Tracer to the proper ter­minals on the UCM. There is no polarity requirement for this connection.

4. At the UCM, the shield should be cut off and taped to prevent any contact
between the shield and ground.

Note: On multiple unit installations, connect the shield between each “daisy­chained” UCM in the system to the shield of the twisted-pair leads going to
the next unit in line. Tape the spliced connection to prevent any contact
between the shield and ground. At the last UCM on the link, the shield
should be cut off and taped.

Ice Building Control Option

The CGM provides auxiliary control for a customer specified/installed
contact closure for ice making. When this field installed normally open
contact (5K86) is provided, the chiller will run normally. Upon contact
closure, the unit will operate fully loaded until the entering water temperature
falls below the pre-programmed ice building setpoint. High quality silver or
gold-plated contacts are recommended. The field supplied contacts must be
compatible with 24 VDC, 12 mA resistive load.

Connect the 5K86 relay contacts to the proper terminals on 1TB4 as
illustrated in Figure 20A. Refer to the latest version of CGAF-IOM-2 for more
complete details.

Compressor Inhibit / KW Limit

The unit is equipped with a 0-5V GBAS and a TCI module, the customer
provided/installed remote contact (5K89) initiates the demand limit function.
When the contact is “Open”, the chiller will operate normally. When the
contact closes, the unit will be limited to the programmed operating capacity
(25%, 50%, 75%, or 100%). When the contact opens, normal chiller
operation is restored.

High quality silver or gold-plated contacts are recommended. These
customer-supplied contacts must be compatible with 24 VDC, 12 mA
resistive load. Refer to the wire selection Table 6 for proper wire size and
Figure 20B for proper termination points.

Connect the wiring from the field supplied normally open contacts between
terminals 5 and 6 on 1TB16, if when 0 - 5 Volt BGAS is installed.

46 CSRA-SVX02A-EN

Installation

Figure 20A — Typical Field Control Connections Diagram

CSRA-SVX02A-EN 47

Installation

Figure 20B — Typical GBAS 0 - 5 Volt Connections Diagram

48 CSRA-SVX02A-EN

Installation

Field Connection Diagram Notes for all System Control Options

CSRA-SVX02A-EN 49

Installation

Use the checklist provided below in conjunction with the “General Unit
Requirement Checklist“ to ensure that the unit is properly installed and ready
for operation. Be sure to complete all of the procedures described in this
section before starting the unit for the first time.

[ ] Turn the field supplied disconnect switch, located upstream of the unit, to
the “Off” position.

WARNING

Hazardous Voltage!

Disconnect all electric pow er, including remote disconnects before
servicing. Follow proper lockout/tagout procedures to ensure the pow er
can not be inadvertently energized. Failure to disconnect power before
servicing could result in death or serious injury.

[ ] Turn the “System” selection switch (at the Remote Panel) to the “Off”
position and the “Fan” selection switch (if applicable) to the “Auto” or “Off”
position.

[ ] Check all electrical connections for tightness and “point of termination”
accuracy.

[ ] Verify that the condenser airflow will be unobstructed.

[ ] Check the condenser fan blades. Ensure they rotate freely within the fan
orifices and are securely fastened to the fan motor shaft.

[ ] Verify that all compressor service valves, discharge service valves, and
liquid line service valves are back seated on each circuit.

CAUTION
Compressor Damage!

Compressor service valves must be fully opened before start-up
(suction, discharge, liquid line, and oil line). Failure to fully open valves
prior to start-up may cause compressor failure due to lack of refrigerant
and/or oil flow .

[ ] Inspect the interior of the unit for tools and debris.

[ ] Fill the chilled water system.

[ ] Vent the chilled water system at the highest points in the system. Vent the
air out of the chiller barrel by opening the vent, located on the top of the
chiller barrel. Close the vent when the chiller barrel is full of water.

[ ] Once the system has been filled, inspect the entire chilled water piping
system for leaks. Make any necessary repairs before proceeding.

50 CSRA-SVX02A-EN

System Pre-Start
Procedures

Note: To avoid possible equipment damage, do not use untreated or

improperly treated system water.

Voltage Imbalance

Excessive three phase voltage imbalance between phases will cause motors
to overheat and eventually fail. The maximum allowable voltage imbalance is
2%. Measure and record the voltage between phases 1, 2, and 3 and
calculate the amount of imbalance as follows:

% Voltage Imbalance = where;

AV (Average Voltage) =

V1, V2, V3 = Line Voltage Readings

VD = Line Voltage reading that deviates the farthest from the average
voltage.

Example: If the voltage readings of the supply power measured 221, 230,
and 227, the average volts would be:

VD (reading farthest from average) = 221

The percentage of Imbalance equals:

The 2.2% imbalance in this example exceeds the maximum allowable
imbalance of 2.0%. This much imbalance between phases can equal as
much as a 20% current imbalance with a resulting increase in motor winding
temperatures that will decrease motor life. If the voltage imbalance is over
2%, notify the proper agencies to correct the voltage problem before
operating this equipment.

AVVD–

100

----------------------

AV

Volt1 Volt2 Volt3++

--------------------------------------------------------

221230227++

--------------------------------------- 226Avg

100

3

3

226221–

------------------------ 2.2=
226

=

·

Scroll Compressor Current Imbalance

Typically, current imbalance is associated with loss in motor efficiency,
higher operating motor temperature, loss of performance and reliability.

With the designs of specialized motors such as those used in the Trane
scroll compressor, operating temperature, efficiency, performance, and
reliability has been taken into account in the total performance of the
compressor.

Current imbalance in a scroll compressor can typically vary from 4 to 15
percent with balanced line voltage. This imbalance occurs because not all of
the winding turns see the same amount of stator iron. The variance of iron
within the motor is to accommodate design requirements for motor cooling
and oil return.

CSRA-SVX02A-EN 51

System Pre-Start
Procedures

At low operating voltage and high operating load, the imbalance may be
around 4 percent. At high operating voltage and low operating load, the
imbalance may be as high as 15 percent.

If an imbalance situation is suspected within the compressor (current draw
unequal between phases) and the line voltage imbalance does not exceed 2
percent;

1. Turn the field supplied disconnect switch, located upstream of the unit to
the “Off” position.

WARNING

Hazardous Voltage!

Disconnect all electric power, including remote disconnects before
servicing. Follow proper lockout/tagout procedures to ensure the
power can not be inadvertently energized. Failure to disconnect power
before servicing could result in death or serious injury.

2. Disconnect the compressor leads at the compressor terminals.

3. Measure the resistance of the compressor windings at the compressor
terminals.

The actual resistance measured across each winding is not as important as
the amount of variation between the windings. The actual resistance
measured may vary due to the accuracy of the meter, rounding off of the
resistance readings, and the amount of resistance between the meter leads
and the compressor terminals.

Since the amount of copper in each winding is very consistent, the variance
between the windings should not exceed 7 percent.

Example: Typical 10 Ton, 460 volt, 60 Hz compressor has a winding
resistance of 1.44 to 1.09 Ohms.

Electrical Phasing

Unlike traditional reciprocating compressors, scroll compressors are phase
sensitive. Proper phasing of the electrical supply to the unit is critical for
proper operation and reliability.

The compressor motor is internally connected for clockwise rotation with the
incoming power supply phased as A, B, C.

Proper electrical supply phasing can be quickly determined and corrected
before starting the unit by observing the red phase monitor light on the chiller
control panel door and following the steps below

[ ] Turn the field supplied disconnect switch that provides power to the chiller
circuit breaker t the “OFF” position.

52 CSRA-SVX02A-EN

System Pre-Start
Procedures

[ ] Open switch (1S70), 24V Transformer SW and close switch (1S1), 115V
control circuit SW inside chiller control panel.

[ ] Close the disconnect switch or circuit protector switch that provides the
supply power to the unit's chiller circuit breaker.

[ ] Turn chiller circuit breaker handle on main control panel door to the “ON”
position.

[ ] Observe if “RED” light is illuminated on outside of chiller control panel. If
red light is not illuminated, push red light to test if illumination occurs. If
illumination occurs only when pushed, then phases are correct. If red light is
illuminated, open the field disconnect switch or circuit breaker protection
switch and reverse any two power wires.

High voltage is present at chiller circuit breaker 1CB1.

WARNING

Live Electrical Components!

During installation, testing, servicing and troubleshooting of this product,
it may be necessary to w ork w ith live electrical components. Have a
qualified licensed electrician or other individual w ho has been properly
trained in handling live electrical components perform these tasks.
Failure to follow all electrical safety precautions w hen exposed to live
electrical components could result in death or serious injury.

CSRA-SVX02A-EN 53

System Start-Up

Sequence of Operation

Chiller Control for Comfort Applications

The CGM controls the leaving solution temperature (LST) to within an
adjustable setpoint using deadband control. The CGM monitors the LST
sensor and determines how far away the temperature is from the leaving
solution setpoint (LSS). The compressors are staged On/Off depending on
where the LST is within the control deadband.

Deadband Calculation

The rate at which capacity stages are added or subtracted is determined by
a control algorithm The CGM control deadband for comfort applications is a
calculated value based upon the control response setpoint, the difference
between LSS and LST, the number of capacity steps, the design delta
temperature (DDT) of the system, and the number of capacity steps. The
minimum comfort deadband is 1 degree F. The maximum comfort deadband
above or below the LSS is 10°F for a two stage unit and 5°F for a 4 stage
unit.

When the LST is inside the control deadband, the calculation is cleared and
no response is initiated. When the LST is outside the deadband and the
calculated control algorithm value equals 1, a capacity add command is
initiated. Conversely, when the value of the control algorithm equals -1, a
capacity subtract command is initiated. Once a capacity add or subtract
command is given and a change in the compressor staging has been
detected, the value of the control algorithm is reset to 0.

Chiller Freeze Protection

The CGM prevents evaporator fluid from freezing by utilizing two separate
algorithms. One is the evaporator limit control algorithm which stages
compressors “Off” if violated and the other is the evaporator freeze
protection algorithm which activates auto/manual diagnostics if violated. The
freeze protection function will always operate as long as the unit is in the
Auto mode for both normal cooling applications and/or ice building modes. A
manual reset diagnostic will occur if all compressors are shut off due to a
freeze protection violation.

The evaporator limit control integrator (ELCI) algorithm calculates a value
based upon the low leaving solution temperature cutout setpoint and the
leaving solution temperature. When the value for ELCI drops below -1, the
unit control will reduce the chiller capacity by staging down and/or inhibiting
a compressor from operation. After each capacity subtract command from
the capacity control algorithm is issued, ELCI is increased by 1 and retained.
The ELCI is set to 0 any time the leaving solution temperature is greater than
or equal to the low leaving solution temperature cutout (LLSC) + 3°F.
Compressors will be prevented from operating until the leaving solution
temperature (LST) is 4°F above the LLSC.

If Pumpdown is enabled and a subtract command is issued, the circuit will
be allow to pumpdown.

54 CSRA-SVX02A-EN

System Start-Up

Evaporator Freeze Protection Diagnostic

The evaporator freeze protection integrator (EFZ) will start integrating when
the leaving solution temperature is less than the low leaving solution
temperature cutout setpoint. Once EFZ integrates up to 30 Sec., the
following diagnostics will occur:

1. If all compressors are off, an auto diagnostic will occur. All of the com­pressors will be prevented from operating until the LST is 4°F greater
than the LLSC. Once the LST is 4°F above the LLSC, the unit will allow
normal unit operation.

2. If any compressors are “On”, a manual diagnostic will occur. All of the
compressors will be shutdown and locked out due to the violation of the
evaporator freeze protection.

Sequence of Operation

Chiller Control for Process Applications

Process applications are characterized as having fast changes in load and
these loads are not adequately controlled with the same scheme used for
comfort applications. To provide better control of these dynamic loads, a
Proportional + Integral “control to setpoint” (as opposed to “control to
deadband”) control strategy is used. System reliability is inversely
proportional to compressor cycle rates so reliability is the driving factor for
determining maximum cycle rate which ultimately translates into cycle-to­cycle leaving solution temperature swings.

To provide stable capacity control, a 1 minute minimum time between
compressor starts is required. The control will determine an estimate of
instantaneous load based on error from setpoint for the leaving solution
temperature and cycle the appropriate compressor stage to best match the
calculated load.

Determining instantaneous error:

Error = Chiller Solution Temp - Chiller Solution Setpoint.

PI Control Calculation:

The CGM calculates the Load Value by applying PI calculations to the
instantaneous error value. The Load Value consists of an integer part and a
fractional part. The integer part represents which compressor stages are
locked “On” and the fractional part represents the duty cycle required for the
next higher compressor stage. For a 4 compressor unit, the Load Value will
range from 0.0 to 4.0. For a 2 compressor unit, the Load Value will range
from 0.0 to 2.0.

CSRA-SVX02A-EN 55

System Start-Up

Duty Cycle Calculations calculate the duty cycle based on the calculated
Load Value Fraction:

On Time
Seconds = 3600 / 4 X Max Cycle Rate X (1-Load Value Fraction)

Off Time
Seconds = 3600 / 4 X Max Cycle Rate X Load Value Fraction

Where Load Value Fraction = Fractional part of the calculated Load Value.

Sequence of Operation

Leaving Solution Reset (LSR)

Leaving Solution Reset (LSR) refers to the process of adjusting the Leaving
Solution Setpoint (LSS) based on an external temperature.

When the optional Leaving Solution Reset (LSR) feature is used, the CGM
will automatically adjust the LSS in response to a temperature change from
one of three different temperature sensor:

1. Zone Temperature sensor

2. Outside Air Temperature sensor

3. Entering Solution Temperature sensor.

The reset temperature value (Start Temperature), to start resetting the
Leaving Solution Setpoint (LSS) and the maximum amount of reset to be
applied to the LSS is programmable through the Human Interface. The reset
amount applied to the LSS is a linear calculation between the Start
Temperature and the End Temperature. After the reset amount has been
calculated, it is added to the Leaving Solution Setpoint to create the Leaving
Solution Reset Setpoint. If the solution temperature is above the selected
Start Temperature, the reset amount is zero. If the solution temperature is
below the End Temp, the maximum amount of reset is applied. For reset
type 'None', the amount of reset is zero. Refer to the appropriate reset type
in Table 8 for reset schedules.

56 CSRA-SVX02A-EN

System Start-Up

Table 8a — Chilled Solution Reset Schedule based on Zone
Temperature

Reset
Amount = Maximum
LSS = ALSS + Maximum

Active Leaving

Solution Setpoint

Zone Reset Cooling

Factory

Preset = 5

Reset
Amount = Zero (0)
LSS = ALSS

Reset
Amount = Maximum
LSS = ALSS + Maximum

Factory

Preset = 5

Adjustable

Reset

3 - 16 F

End Temperature
Range 66 - 81
Factory Preset = 75

Start Temperature
Range 66 - 81
Factory Preset = 78

Zone

Temperature

Table 8b — Chilled Solution Reset Schedule based on Outside Air
Temperature

Active Leaving

Solution Setpoint

Adjustable

Reset

3 - 16 F

Outside Air Reset Cooling

Reset
Amount = Zero (0)
LSS = ALSS

CSRA-SVX02A-EN 57

End Temperature
Range 65 - 125
Factory Preset = 70

Start Temperature
Range 65 - 125
Factory Preset = 90

OA

Temperature

System Start-Up

Table 8c — Chilled Solution Reset Schedule based on Entering
Solution Temperature

Reset
Amount = Maximum
LSS = ALSS + Maximum

Active Leaving

Solution Setpoint

Entering Solution Reset

Factory

Preset = 5

Reset
Amount = Zero (0)
LSS = ALSS

Adjustable

Reset

3 - 16 F

End Temperature
Range 4 - 19
Factory Preset = 8

Start Temperature
Range 4 - 19
Factory Preset = 10

EST - LST

Temperature

Sequence of Operation

Lead/Lag (Standard)

When Lead-Lag is enabled, for each capacity add request, the CGM will
begin sequencing the compressors “On” that have:

A. the least number of starts; or,

B. the least run time (if number of starts are equal)

At each capacity subtract request, the CGM will begin sequencing the
compressors “Off” that have:

A. the most run time; or,

B. the least number of starts (if more than one compressor has the same run

time)

If a compressor is locked out for any reason when a capacity add request
occurs, the next available compressor which meets the specified criteria will
be started.

If a compressor can not be turned “Off” due to the minimum “On Time”, the
next compressor which meets the specified criteria will be turned “Off”.

On dual circuit units, as the first two capacity add requests are initiated, one
compressor on each circuit will start before any additional compressors on
any circuit is started. When staging down from three compressor stages to
two compressor stages, the CGM will turn a compressor “Off” on the circuit
that has the most compressors operating.

58 CSRA-SVX02A-EN

System Start-Up

With Lead/Lag enabled, HGBP operation (if applicable) will be bypassed and
the system will go directly into pumpdown when the last subtract command
is initiated.

When the UCM is powered up (after a power loss), or any time the
compressor's start time and run time are equal, the number one (Lead)
designated compressor will be the first “On” and the number two (lag)
designated compressor will be the first “Off” on single circuit units (20 - 30
Tons).

For dual circuit units (40 through 60 Tons), the “On” sequence will be A-C-B­D and the “Off” sequence will be D-B-C-A under the previously described
conditions. Refer to Figure 23 for compressor locations.

Sequence of Operation

Condenser Fan Control

The CGM condenser fan control logic is dependent on the number of
compressors operating per circuit and the saturated condensing
temperature. Fan logic is not initiated until the low ambient start time has
elapsed.

The condenser fan contactors, located in the unit control panel, initiate fan
operation when energized. Refer to Figure 22 for the condenser fan
locations and fan contactor designators. Dashed lines connecting pairs of
fans indicate instances where one contactor controls both fans.

Sequence of Operation

Low Ambient Dampers

Low Ambient Dampers are used to extend the operation of these units from
the standard operational temperatures to a minimum of 0°F without hot gas
bypass or 10°F with hot gas bypass. (These values apply when wind speed
across the condenser coil is less than 5 m.p.h.). If typical wind speeds are
higher than 5 m.p.h., a wind screen around the unit may be required. By
restricting the airflow across the condenser coils, saturated condensing
temperatures can be maintained as the ambient temperatures change.

The low ambient damper actuator controls damper modulation for each
refrigerant circuit in response to saturated condensing temperature.

Chilled Water Circulating Pump

Once the system has been filled, complete the following chilled water system
start-up procedures.

1. Turn the 115 volt control circuit switch 1S1 and the 24 volt control circuit
switch 1S70 located in the unit control panel to the “Off” position.

2. Turn the chiller circuit breaker (1CB1) and the pump circuit breaker on the
pump starter panel, to the “On” position.

3. Close the field supplied main power disconnect switch or circuit protector
switch that provides the supply power to the unit's circuit breaker (1CB1).

CSRA-SVX02A-EN 59

System Start-Up

4. Turn the 24 volt control circuit switch 1S70 located in the unit control
panel to the “On” position.

Note: To prevent the compressors from starting, leave the 115 volt control
circuit switch “Off”.

5. Open the Human Interface access door, located in the unit control panel,
and press the SERVICE MODE key to display the first service screen.
Refer to the latest edition of the CGAF-PTG manual for the SERVICE
TEST screens and programming instructions.

6. Use Table 10 to program the solution pump for operation by scrolling
through the displays.

7. Once the configuration for the pump is complete, press the NEXT key
until the LCD displays the “Start test in __Sec.” screen. Press the + key to
designate the delay before the test is to start. This service test will begin
after the TEST START key is pressed and the delay designated in this
step has elapsed. Press the ENTER key to confirm this choice.

WARNING

Rotating Components!

During installation, testing, servicing and troubleshooting of this product
it may be necessary to check rotating components. Have a qualified or
licensed service individual w ho has been properly trained in handling
exposed rotating components, perform these tasks. Failure to follow all
safety precautions w hen exposed to rotating components could result in
death or serious injury.

Make sure all personnel are standing clear of the unit before proceeding.
The programmed components will start when the TEST START time
designated in the previous step has elapsed.

8. Press the TEST START key to start the test. Remember that the delay
designated in Step 7 must elapse before the pump will begin to operate.

9. To balance the flow through the evaporator, adjust the flow rates between
the minimum and maximum values given in Table 9. Flow rates above or
below these values can cause equipment damage or improper unit oper­ation.

10.Check the flow device (if applicable) on the evaporator outlet piping to
ensure it opens and closes properly.

11.Measure the evaporator water pressure drop at the system pressure
gauge(s). Compare the readings to the pressure drop values given in Fig­ure 21.

Note: Evaporator pressure drop is an approximation and is to be used as a
tool to estimate flow rate and as an aid to waterside system piping design. If
an accurate measurement of flow is required, a flow meter must be installed
in the system.

60 CSRA-SVX02A-EN

45.00

40.00

35.00

30.00

25.00

System Start-Up

Table 9 — Evaporator Data for C25 through C60 Units

Unit Size Water Volume Minimum Flow Rate Maximum Flow Rate

gal liter gpm liter/s gpm liter/s

C60 37.8 143 72 4.5 216 13.6

Figure 21 — Evaporator Water Pressure Drop for CGAF-C20 through
C60 Units (English)

C60 Ton

C25 Ton

C40 Ton

20.00

15.00

Pressure Drop (Feet of Water)

10.00

5.00

0.00
0 50 100 150 200 250

Flow Rate (GPM)

Note 1: Factor to convert “Feet of Water” to “Lbs. per Sq. Inch” (PSI): 2.3

Feet of Water = 1 PSI

CSRA-SVX02A-EN 61

System Start-Up

COMPONENT

COMPONENT CONFIGURATION

BEING TESTED

Condenser

Compressor Stage

Low Ambient

Liquid Line

Solution

Fans1234

Damper Output

Solenoid Valve

Pump

* COMPRESSOR

20 thru 30 Ton

A

A-Off/B-On

K10-Off

K11-On

N/A

N/A0%OnOnB

A-On/B-Off

K10-On

K11-Off

N/A

N/A0%OnOn40 thru 60 Ton

1A

1A-Off/1B-On

K11-Off

K3-Off

K12-On

K4-Off

0%

Ckt #1 On

On

2A-Off/2B-Off

1B

1A-On/1B-Off

K11-On

K3-Off

K12-Off

K4-Off

0%

Ckt #1 On

On

2A-Off/2B-Off

2A

1A-Off/1B-Off

K11-Off

K3-Off

K12-Off

K4-On

0%

Ckt #2 On

On

2A-Off/2B-On

2B

1A-Off/1B-Off

K11-Off

K3-On

K12-Off

K4-Off

0%

Ckt #2 On

On

2A-On/2B-Off

25 Ton

A-2B1

A-On/B-Off

Off

Off

Off

Off

100%

Ckt #1/2 Off

Off

B-2B2/2B3

A-Off/B-On

Off

Off

Off

Off

100%

Ckt #1/2 Off

Off

40 Ton

1A-2B1

1A-On/1B-Off

Off

Off

Off

Off

100%

Ckt #1/2 Off

Off

2A-Off/2B-Off

1B-2B2

1A-Off/1B-On

Off

Off

Off

Off

100%

Ckt #1/2 Off

Off

2A-Off/2B-Off

2A-2B4

1A-Off/1B-Off

Off

Off

Off

Off

100%

Ckt #1/2 Off

Off

2A-On/2B-Off

2B-2B5

1A-Off/1B-Off

Off

Off

Off

Off

100%

Ckt #1/2 Off

Off

2A-Off/2B-On

50 & 60 Ton

1A-2B1

1A-On/1B-Off

Off

Off

Off

Off

100%

Ckt #1/2 Off

Off

2A-Off/2B-Off

1B-2B2/2B3

1A-Off/1B-On

Off

Off

Off

Off

100%

Ckt #1/2 Off

Off

2A-Off/2B-Off

2A-2B4

1A-Off/1B-Off

Off

Off

Off

Off

100%

Ckt #1/2 Off

Off

2A-On/2B-Off

2B-2B5/2B6

1A-Off/1B-Off

Off

Off

Off

Off

100%

Ckt #1/2 Off

Off

2A-Off/2B-On

CGM Evap Solution

1A-Off/1B-Off

Off

Off

Off

Off0%Ckt #1/2 Off

On

* - Compressors for the 20 thru 60 Ton units can operate individually or together and in any order while in the SERVICE

TEST mode.

Note:

Do Not operate the compressors for extended periods of time without the condenser fans, High

Head Pressure will develop.

** - Condenser fan outputs can operate individually or together and in any order while in the SERVICE TEST mode.

Table 10 — Service Test Guide for Component Operation

62 CSRA-SVX02A-EN

System Start-Up

Verifying Proper Fan Rotation

1. Close the main power disconnect switch or circuit protector switch that
provides the supply power to the unit's circuit breaker (1CB1).

2. Open the Human Interface access door, located in the unit control panel,
and press the SERVICE MODE key to display the first service screen.
Refer to the latest edition of the CGAF-PTG manual for the SERVICE
TEST screens and programming instructions.

3. Use Table 10 to program the condenser fans for operation by scrolling
through the displays. All of the condenser fans can be programmed to be
“On”, if desired. Verify proper fan rotation for VFD's with bypass.

Refer to Figure 22 for the condenser fan locations and the Human Inter­face designator.

4. Once the configuration for the Fans is complete, press the NEXT key until
the LCD displays the “Start test in __Sec.” screen. Press the + key to des­ignate the delay before the test is to start. This service test will begin after
the TEST START key is pressed and the delay designated in this step
has elapsed. Press the ENTER key to confirm this choice.

WARNING

Rotating Components!

During installation, testing, servicing and troubleshooting of this product
it may be necessary to check rotating components. Have a qualified or
licensed service individual w ho has been properly trained in handling
exposed rotating components, perform these tasks. Failure to follow all
safety precautions w hen exposed to rotating components could result in
death or serious injury.

Make sure all personnel are standing clear of the unit before proceeding.
The system components will start when the designated TEST is initiated.

5. Press the TEST START key to start the test. Remember that the delay
designated in Step 4 must elapse before the fans will begin to operate.

6. Check the supply fan and the exhaust fans (if equipped) for proper rota­tion. The direction of rotation is indicated by an arrow on the fan hous­ings. Check the condenser fans for clockwise rotation when viewed from
the top.

If all of the fans are rotating backwards;

A. Press the STOP key at the Human Interface Module in the unit control pan-

el to stop the fan operation.

B. Open the field supplied disconnect switch upstream of the unit. Lock the

disconnect switch in the open position while working at the unit.

CSRA-SVX02A-EN 63

System Start-Up

WARNING

Hazardous Voltage!

Disconnect all electric power, including remote disconnects before
servicing. Follow proper lockout/tagout procedures to ensure the
power can not be inadvertently energized. Failure to disconnect power
before servicing could result in death or serious injury.

C. Interchange any two of the field connected main power wires at the unit cir-

cuit breaker (1CB1).

Note: Interchanging “Load” side power wires at the fan contactors will only
affect the individual fan rotation. Ensure that the voltage phase sequence at
the main terminal block 1TB1 or the factory mounted disconnect switch 1S14
is ABC as outlined in the “Electrical Phasing” section.

If some of the fans are rotating backwards;

A. Press the STOP key at the Human Interface Module in the unit control pan-

el to stop the fan operation.

B. Open the field supplied disconnect switch upstream of the unit. Lock the

disconnect switch in the open position while working at the unit.

C. Interchange any two of the fan motor leads at the contactor for each fan

that is rotating backwards

64 CSRA-SVX02A-EN

System Start-Up

Figure 22 — Condenser Fan Locations

CSRA-SVX02A-EN 65

System Start-Up

Compressor Start-Up

1. Ensure that the main power disconnect switch and the control power cir­cuit breaker for the “System Solution Pump” is “On”.

2. Before closing the main power disconnect switch for the unit, ensure that
the compressor discharge service valve and the liquid line service valve
for each circuit is back seated.

CAUTION

Compressor Damage!

Compressor service valves must be fully opened before start-up
(suction, discharge, liquid line, and oil line). Failure to fully open valves
prior to start-up may cause compressor failure due to lack of refrigerant
and/or oil flow .

3. Remove the protective plastic coverings that shipped over the compres­sors.

4. Check the compressor oil levels. The oil level in each manifolded set of
compressor sight glasses should be equally 1/2 to 3/4 full when they are
“Off”.

5. Check the condenser coils. They should be clean and the fins should be
straight. Straighten any bent coil fins with an appropriate sized fin comb.

6. Turn the main power disconnect switch or circuit protector switch that
provides the supply power to the unit’s terminal block 1TB1 or the unit
mounted disconnect switch 1S14 to the “On” position.

7. Turn the 24 volt control circuit switch 1S70 to the “On” position.

8. Open the Human Interface access door, located in the unit control panel,
and press the SERVICE MODE key to display the first service screen.
Refer to the latest edition of the CGAF-PTG for the SERVICE TEST
screens and programming instructions.

9. Use Table 10 to program the following system components for operation
by scrolling through the displays;

20 through 30 Ton

Compressor 1A (On) Compressor 1A (On)

Compressor 1B (Off) Compressor 1B (Off)

Condenser Fans (On) Compressor 2A (Off)

Solution Pump (On) Compressor 2B (Off)

66 CSRA-SVX02A-EN

40 through 60 Ton

Condenser Fans (On)

Solution Pump (On)

System Start-Up

10.Attach a set of service gauges onto the suction and discharge gauge
ports for each circuit. Refer to Figure 23 for the various compressor loca­tions.

11.Once the configuration for the components is complete, press the NEXT
key until the LCD displays the “Start test in __Sec.” screen. Press the +
key to designate the delay before the test is to start. This service test will
begin after the TEST START key is pressed and the delay designated in
this step has elapsed. Press the ENTER key to confirm this choice.

WARNING

Rotating Components!

During installation, testing, servicing and troubleshooting of this product
it may be necessary to check rotating components. Have a qualified or
licensed service individual w ho has been properly trained in handling
exposed rotating components, perform these tasks. Failure to follow all
safety precautions w hen exposed to rotating components could result in
death or serious injury.

Make sure all personnel are standing clear of the unit before proceeding.
The programmed components will start when the TEST START time
designated in the previous step has elapsed.

12.Turn the 115 volt control circuit switch 1S1 “On”.

13.Press the TEST START key to start the test. Remember that the delay
designated in step 11 must elapse before the system will begin to oper­ate.

14.Once each compressor or compressor pair has started, verify that the
rotation is correct. If a scroll compressor is rotating backwards, it will not
pump and a loud rattling sound can be observed. Check the electrical
phasing at the load side of the compressor contactor.

If the phasing is correct, before condemning the compressor, interchange
any two leads to check the internal motor phasing. Refer to the illustration
in Figure 24 for the compressor terminal identification. If the compressor
runs backward for an extended period (15 to 30 minutes), the motor wind­ings can over heat and cause the motor winding thermostats to open.
This will cause a “compressor trip” diagnostic and stop the compressor.

15.Verify that the oil level in each compressor is correct. The oil level may be
down to the bottom of the sightglass but should never be above the sight­glass.

16.Press the STOP key at the Human Interface Module in the unit control
panel to stop the compressor operation.

17.Repeat steps 8 through 16 for each compressor stage and the appropri­ate condenser fans.

CSRA-SVX02A-EN 67

System Start-Up

Verifying Proper Refrigerant Charge

1. Attach a set of service gauges onto the suction line and liquid line gauge
ports for each circuit. Refer to Figure 23 for the various compressor loca­tions.

2. Open the Human Interface access door, located in the unit control panel,
and press the SERVICE MODE key to display the first service screen.
Refer to the latest edition of the CGAF-PTG for the SERVICE TEST
screens and programming instructions.

3. Use Table 10 to program the following system components for the num­ber 1 refrigeration circuit by scrolling through the displays;

Chilled Solution Pump (On)

All Compressors for each circuit (On)

Condenser Fans for each circuit (On)

Hot Gas Bypass (Disabled, if applicable)

Low Ambient Dampers (100%, if applicable)

4. Once the configuration for the components is complete, press the NEXT
key until the LCD displays the “Start test in __Sec.” screen. Press the +
key to designate the delay before the test is to start. This service test will
begin after the TEST START key is pressed and the delay designated in
this step has elapsed. Press the ENTER key to confirm this choice.

WARNING

Rotating Components!

During installation, testing, servicing and troubleshooting of this product
it may be necessary to check rotating components. Have a qualified or
licensed service individual w ho has been properly trained in handling
exposed rotating components, perform these tasks. Failure to follow all
safety precautions w hen exposed to rotating components could result in
death or serious injury.

Make sure all personnel are standing clear of the unit before proceeding.
The programmed components will start when the TEST START time
designated in the previous step has elapsed.

5. Press the TEST START key to start the test. Remember that the delay
designated in step 4 must elapse before the system will begin to operate.

6. After all of the compressors and condenser fans for the number 1 circuit
have been operating for approximately 30 minutes, observe the operat­ing refrigerant pressures and measure the system superheat and sub­cooling.

The outdoor ambient temperature must be between 65°F and 105°F.
When the temperatures are outside of these ranges, refer to Table 10 for
the recommended refrigerant capacities.

68 CSRA-SVX02A-EN

System Start-Up

Environmental scientists have found evidence that refrigerant emissions
contribute to depletion of ozone in the upper atmosphere and can increase
global warming. Trane encourages every effort to eliminate, if possible, or
vigorously reduce the emission of CFC, HCFC and HFC refrigerant to the
atmosphere that can result from installation, operation, routine maintenance,
or major service on this equipment. Only technicians with EPA certification
should be allowed to handle CFC, HCFC or HFC refrigerants. Compliance or
certification to other local or state codes may also be required when handling
refrigerants. Always act in a responsible manner to conserve refrigerants.

Refer to general service bulletin MSCU-SB-1 (latest edition).

Subcooling

With the unit operating at “Full Circuit Capacity”, acceptable subcooling
ranges between 14°F to 22°F.

Measuring Subcooling

A. At the liquid line service valve, measure the liquid line pressure. Using a

Refrigerant 22 pressure / temperature chart, convert the pressure reading
into the corresponding saturated temperature.

B. Measure the actual liquid line temperature as close to the liquid line service

valve as possible. To ensure an accurate reading, clean the line thoroughly
where the temperature sensor will be attached. After securing the sensor
to the line, insulate the sensor and line to isolate it from the ambient air.

Note: Glass thermometers do not have sufficient contact area to give an
accurate reading.

C. Determine the system subcooling by subtracting the actual liquid line tem-

perature (measured in b) from the saturated liquid temperature (converted
in a).

Superheat

The reliability and performance of the refrigeration system is heavily
dependent upon proper expansion valve adjustment. Therefore, the
importance of maintaining the proper superheat cannot be over emphasized.
Accurate measurements of superheat will provide the following information.

A. How well the expansion valve is controlling the refrigerant flow.

B. The efficiency of the evaporator.
C. The amount of protection the compressor is receiving against flooding or

overheating.

The recommended range for superheat is 10 to 16 degrees at the
evaporator.

Systems operating with less than 10 degrees of superheat:

A. Could cause serious compressor damage due to refrigerant floodback.

B. Removes working surface from the evaporator normally used for heat

transfer.

CSRA-SVX02A-EN 69

System Start-Up

Systems operating with superheat in excess of 16 degrees:

A. Could cause excessive compressor cycling on internal winding thermostat

which leads to compressor motor failure.

B. Lowers the efficiency of the evaporator by reducing the heat transfer ca-

pability.

Measuring Superheat

A. Measure the suction pressure at the suction line gauge access port locat-

ed near the compressor.

B. Using a Refrigerant / Temperature chart, convert the pressure reading to

a corresponding saturated vapor temperature.

C. Measured the suction line temperature as close to the expansion valve

bulb, as possible.

D. Subtract the saturated vapor temperature obtained in Step B from the ac-

tual suction line temperature obtained in step c. The difference between the
two temperatures is known as “superheat”.

Note: When adjusting superheat, recheck the system subcooling before
shutting the system “Off”.

7. Once the checks and adjustments for the operating circuit has been com­pleted, check and record the:

ambient temperature;
compressor oil level (each circuit);
compressor suction and discharge pressures (each circuit);
superheat and subcooling (each circuit);

Record this data on an “Operator's Maintenance Log” shown in Table 12.

8. Press the STOP key at the Human Interface Module in the unit control
panel to stop the system operation.

9. Repeat Steps 1 through 8 for the number 2 refrigeration circuit.

10.After shutting the system off, check the compressor's oil's appearance.
Discoloration of the oil indicates that an abnormal condition has occurred.
If the oil is dark and smells burnt, it has overheated because of: compres­sor is operating at extremely high condensing temperatures; high super­heat; a compressor mechanical failure; or, occurrence of a motor
burnout.

If the oil is black and contains metal flakes, a mechanical failure has
occurred. This symptom is often accompanied by a high compressor
amperage draw.

If a motor burnout is suspected, use an acid test kit to check the condition
of the oil. Test results will indicate an acid level exceeding 0.05 mg
KOH/g if a burnout occurred.

70 CSRA-SVX02A-EN

System Start-Up

Compressor Oil

The scroll compressor uses Trane OIL-42 without substitution
appropriate oil charge for a 9 and 10 Ton scroll compressor is 8.5 pints. For a
14 and 15 Ton scroll compressor, use 13.8 pints.

Table 11 — Recommended Refrigerant Capacities

Unit Size Refrigerant

Charge*

C25 54.0

C40 38.0

C60 67.0

* The listed refrigerant charge is for pounds per circuit.

Figure 23 — Typical Compressor Locations

. The

CSRA-SVX02A-EN 71

System Start-Up

Figure 24 — Typical Compressor Terminal Block

Compressor Crankcase Heaters

Each compressor is equipped with a crankcase heater and is controlled by a
600 volt auxiliary switch on the compressor contactor. The proper operation
of the crankcase heater is important to maintain an elevated compressor oil
temperature during the “Off” cycle to reduce oil foaming during compressor
starts.

When the compressor starts, the sudden reduction in crankcase pressure
causes the liquid refrigerant to boil rapidly causing the oil to foam. This
condition could damage compressor bearings due to reduced lubrication
and could cause compressor mechanical failures.

When power has been “Off” for an extended period, allow the crankcase
heater to operate a minimum of 8 hours before starting the unit. Compressor
crankcase heaters can be energized by supplying 115V power to the shore
power plug (9J1) installed near the chiller control panel.

Low Ambient Damper Adjustment
(Factory or Field Installed)

A damper is factory installed over the lead condenser fan for each
refrigeration circuit. Refer to the appropriate unit illustrated in Figure 22 for
the damper locations.

The UCM has a factory default setpoint of 90°F. This setpoint can be
adjusted using the Human Interface programming procedures.

Inspect the damper blades for proper alignment and operation. Dampers
should be in the closed position during the “Off” cycle. If adjustment is
required;

1. At the Human Interface, program the actuator for 0% on circuit #1 and/or
circuit #2. (The output signal will go to 0.0 VDC.)

72 CSRA-SVX02A-EN

System Start-Up

2. Loosen the damper shaft “Locking” set screws on the actuator.

3. Firmly hold the damper blades in the closed position.

4. Tighten the “Locking” set screws.

To check damper operation, program the actuator for 100% on circuit #1
and/or circuit #2. (The output signal will go to 10 VDC and the damper will
drive to the full open position.

Final System Setup

After completing all of the checkout and start-up procedures outlined in the
previous sections (i.e., operating the unit in each of its Modes through all
available stages of cooling), perform these final checks before leaving the
unit:

[ ] Close the disconnect switch or circuit protector switch that provides the
supply power to the unit's circuit breaker (1CB1).

WARNING

Hazardous Voltage!

Disconnect all electric power, including remote disconnects before
servicing. Follow proper lockout/tagout procedures to ensure the
power can not be inadvertently energized. Failure to disconnect power
before servicing could result in death or serious injury.

[ ] Turn the solution pump control circuit breaker handle to the “Off” position.

[ ] At the Human Interface Module, press the “SETUP” key. The LCD screen
will display various preset “parameters of operation” based on the unit type,
size, and the installed options. Compare the factory preset information to the
specified application requirements. If adjustments are required, follow the
step-by-step instructions provided in the appropriate CGAF-PTG manual

[ ] Program the Night Setback (NSB) panel (if applicable) for proper
unoccupied operation. Refer to the programming instructions for the specific
panel.

[ ] Verify that the Remote panel “System” selection switch, “Fan” selection
switch, and “Zone Temperature” settings for comfort systems are correct.

[ ] Inspect the unit for misplaced tools, hardware, and debris.

[ ] Turn the solution pump control circuit disconnect switch to the “On”
position.

[ ] Press the “AUTO” key at the Human Interface Module to begin system
operation. The system will start automatically once a request for solution
cooling has been initiated.

[ ] Verify that all exterior panels including the control panel doors and
condenser grilles are secured in place.

CSRA-SVX02A-EN 73

System Start-Up

Refrigerant Circuit #1

Refrigerant Circuit #2

Current

Ambient

Compr.

Suct.

Disch.

Liquid

Super-

Sub-

Compr.

Suct.

Disch.

Liquid

Super-

Sub-

Temp.

Oil

Press.

Press.

Press.

heat

cool.

Oil

Press.

Press.

Press.

heat

cool.

Date

(F)

Level

(Psig)

(Psig)

(Psig)

(F)

(F)

Level

(Psig)

(Psig)

(Psig)

(F)

(F)

Note:

Check and record the data requested above each month during the cooling season with the unit running.

Table 12 — Sample Operator’s Maintenance Log

- ok - ok

- low - low

- ok - ok

- low - low

- ok - ok

- low - low

- ok - ok

- low - low

- ok - ok

- low - low

- ok - ok

- low - low

- ok - ok

- low - low

- ok - ok

- low - low

- ok - ok

- low - low

- ok - ok

- low - low

74 CSRA-SVX02A-EN

Service & Maintenance

Compressor Operational Sounds

Because of the scroll compressor design, it emits a higher frequency tone
(sound) than a reciprocating compressor. It is designed to accommodate
liquids, both oil and refrigerant, without causing compressor damage. The
following discussion describes some of the operational sounds that
differentiate it from those typically associated with a reciprocating
compressor. These sounds do not affect the operation or reliability of the
compressor.

At Shutdown:

When a Scroll compressor shuts down, the gas within the scroll expands and
causes momentary reverse rotation until the discharge check valve closes.
This results in a “flutter” type sound.

At Low Ambient Start-Up:

When the compressor starts up under low ambient conditions, the initial flow
rate of the compressor is low due to the low condensing pressure. This
causes a low differential across the thermal expansion valve that limits its
capacity. Under these conditions, it is not unusual to hear the compressor
rattle until the suction pressure climbs and the flow rate increases.

Scroll Compressor Replacement

Table 13 lists the specific compressor electrical data and the circuit breaker
operating ranges.

The compressor manifold system was purposely designed to provide proper
oil return to each compressors. The refrigerant manifolded system must not
be modified in any way.

Note: Altering the manifold piping may cause oil return problems and
compressor failure.

Should a compressor replacement become necessary and a suction line
filter drier is to be installed, install it a minimum of 18 inches upstream of the
oil separator tee. Refer to the illustration in Figure 25.

Anytime a compressor is replaced, the oil for each compressor within the
manifolded set must be replaced.

The scroll compressor uses Trane OIL-42 without substitution. The
appropriate oil charge for a 9 and 10 Ton scroll compressor is 8.5 pints. For a
14 and 15 Ton scroll compressor, use 13.8 pints.

CSRA-SVX02A-EN 75

Service & Maintenance

Important: Environmental scientists have found evidence that refrigerant

emissions contribute to depletion of ozone in the upper atmosphere and can
increase global warming. Trane encourages every effort to eliminate, if
possible, or vigorously reduce the emission of CFC, HCFC and HFC
refrigerant to the atmosphere that can result from installation, operation,
routine maintenance, or major service on this equipment. Only technicians
with EPA certification should be allowed to handle CFC, HCFC or HFC
refrigerants. Compliance or certification to other local or state codes may
also be required when handling refrigerants. Always act in a responsible
manner to conserve refrigerants.

Refer to general service bulletin MSCU-SB-1 (latest edition).

Figure 25 — Suction Line Filter/Drier Installation

76 CSRA-SVX02A-EN

Service & Maintenance

Table 13 — Compressor Circuit Breaker Data

Unit Size Number of

Compressors

C25 1, 1 10, 15 460 17.1, 25.4 117, 178 20.8, 29.5 23.9, 33.9

C40 4 9 460 17.2 117 18.9 21.7

C60 4 15 460 25.4 178 30.7 35.3

Compressor

Capacities

Rated

Voltage

Compressor

RLA

Compressor

LRA

Must Hold

(Amps)

Must Trip

(Amps)

Fuse Replacement Data

Table 14 lists the replacement fuses for the control circuit, compressors, and
condenser fans.

Table 14 — Fuse Replacement Data

Fuse Replacement Table

Condenser Fan Fuse

Time Delay

Control Power Fuse 1F7 Class K5 6.25 Amp

Compressor Protection Fuse 1F44 & 1F45 Type MTH 6 Amp

Transformer Protection Fuse 1F72 Thru 1F74 Type FLQ 15 Amp

Compressor Crankcase

Heater Time Delay Fuse

1F1 Thru 1F6 Class RK5 15A

9F1, 9F2 Class CC 7.5 Amp

Evaporator Heat Tape

9F4 Class CC 5 Amp

Time Delay Fuse

25T Shorepower Fuse

9F3 Class CC 7 Amp

Time Delay

40T Shorepower Fuse

9F3 Class CC 10 Amp

Time Delay

60T Shorepower Fuse

9F3 Class CC 12 Amp

Time delay

CSRA-SVX02A-EN 77

Unit

Size

Number

of

Coils

Service & Maintenance

Monthly Maintenance

Before completing the following checks, turn all system control circuit
switches to the “Off” position.

“Open” the main power disconnect switches for the Condensing Unit and all
system support equipment. “lock” the disconnect switches in the “Off”
position before removing any access panels.

Hazardous Voltage!

Disconnect all electric power, including remote disconnects before
servicing. Follow proper lockout/tagout procedures to ensure the
power can not be inadvertently energized. Failure to disconnect power
before servicing could result in death or serious injury.

Table 15 — Condenser Coil Data

Coil Fin

Configuration

WARNING

Tube

Diameter

Coil

Rows

Fins

per

Foot

Coil
Size

(Inches)

Subcooler

Size

(Inches)

Tube
Type

C25 2 Slit Fin 0.375” 3 144 45 x 71

35 x 71

C40 2 Slit Fin 0.375” 3 144 56 x 70 9 x 70 Smooth

C60 2 Slit Fin 0.375” 4 144 57 x 96 9 x 96 Smooth

Coil Cleaning

Regular coil maintenance, including annual cleaning, enhances the unit's
operating efficiency by minimizing:

• compressor head pressure and amperage draw; evaporator water
carryover; fan brake horsepower, due to increase static pressure
losses; airflow reduction.

At least once each year, or more often if the unit is located in a “dirty”
environment, clean the evaporator and condenser coils using the
instructions outlined below. Be sure to follow these instructions as closely as
possible to avoid damaging the coils.

To clean refrigerant coils, use a soft brush and a sprayer (either a garden
pump-up type or a high-pressure sprayer). A high-quality detergent is also
required; suggested brands include “SPREX A.C.”, “OAKITE 161", “OAKITE
166" and “COILOX”. If the detergent selected is strongly alkaline (ph value
exceeds 8.5), add an inhibitor.

1. Remove enough panels from the unit to gain access to the coil.

14 x 71 Smooth

78 CSRA-SVX02A-EN

Service & Maintenance

2. Protect all electrical devices such as motors and controllers from any
over spray.

3. Straighten any bent coil fins with a fin comb.

4. Mix the detergent with water according to the manufacturer's instructions.
If desired, heat the solution to 150°F maximum to improve its cleansing
capability.

WARNING

Hazardous Pressures!

Coils contain refrigerant under pressure. When cleaning coils, maintain
coil cleaning solution temperature under 150 0 F to avoid excessive
pressure in the coil. Failure to follow these safety precautions could
result in coil bursting, w hich could result in death or serious injury.

5. Pour the cleaning solution into the sprayer. If a high-pressure sprayer is
used:

• do not allow sprayer pressure to exceed 600 psi.

• the minimum nozzle spray angle is 15 degrees.

• maintain a minimum clearance of 6" between the sprayer nozzle and
the coil.

• spray the solution perpendicular (at 90 degrees) to the coil face.

6. Spray the leaving-airflow side of the coil first; then spray the opposite side
of the coil. Allow the cleaning solution to stand on the coil for five minutes.

7. Rinse both sides of the coil with cool, clean water.

8. Inspect both sides of the coil; if it still appears to be dirty, repeat Steps 6
and 7.

9. Reinstall all of the components and panels removed in Step 1 and any
protective covers installed in Step 2.

10.Restore the unit to it's operational status and check system operation.

System operation

[ ] Close the main power disconnect switch for the unit and all system
support equipment. Turn all system control circuit switches to the “On”
position.

WARNING

Rotating Components!

Disconnect all electric pow er, including remote disconnects before
servicing. Follow proper lockout/tagout procedures to ensure the pow er
can not be inadvertently energized. Failure to disconnect power before
servicing could result in death or serious injury.

CSRA-SVX02A-EN 79

Service & Maintenance

Make sure all personnel are standing clear of the unit before proceeding.
The system components will start when the power is applied.

[ ] With the unit running, check and record the:

• ambient temperature;

• compressor oil level (each circuit);

• compressor suction and discharge pressures (each circuit);

• superheat and Subcooling (each circuit);

Record this data on an “operator's maintenance log” similar to the one
illustrated in the “Final Setup” section of this manual. If the operating
pressures indicate a refrigerant shortage, measure the system Superheat
and system Subcooling. For guidelines, refer to the “System Start-Up”
section.

Environmental scientists have found evidence that refrigerant emissions
contribute to depletion of ozone in the upper atmosphere and can increase
global warming. Trane encourages every effort to eliminate, if possible, or
vigorously reduce the emission of CFC, HCFC and HFC refrigerant to the
atmosphere that can result from installation, operation, routine maintenance,
or major service on this equipment. Only technicians with EPA certification
should be allowed to handle CFC, HCFC or HFC refrigerants. Compliance or
certification to other local or state codes may also be required when handling
refrigerants. Always act in a responsible manner to conserve refrigerants.

Refer to general service bulletin MSCU-SB-1 (latest edition).

Annual Maintenance

[ ] Perform all weekly and monthly maintenance procedures.

[ ] Have a qualified service technician check the setting and function of each
control and inspect the condition of and replace compressor and control
contactors if needed.

[ ] If chiller is not piped to drain facilities, make sure drain is clear to carry
away system water.

[ ] Drain water from evaporator and associated piping systems. Inspect all
piping components for leakage, damage, etc. Clean out any in-line water
strainers.

[ ] Clean and repaint any corroded surface.

[ ] Check low ambient dampers for proper operation.

[ ] Clean condenser coils. Refer to “Coil Cleaning”.

80 CSRA-SVX02A-EN

Service & Maintenance

WARNING

Hazardous Voltage!

Disconnect all electric power, including remote disconnects before
servicing. Follow proper lockout/tagout procedures to ensure the
power can not be inadvertently energized. Failure to disconnect power
before servicing could result in death or serious injury.

[ ] Inspect the expansion valve sensing bulbs for cleanliness. Clean if
required. Sensing bulbs must make good contact with suction lines and be
properly insulated.

[ ] Clean condenser fans. Check fan assemblies for proper orifice clearance
and for motor shaft mis-alignment, abnormal end-play or vibration and noise.

WARNING

Rotating Components!

Disconnect all electric pow er, including remote disconnects before
servicing. Follow proper lockout/tagout procedures to ensure the pow er
can not be inadvertently energized. Failure to disconnect power before
servicing could result in death or serious injury.

CSRA-SVX02A-EN 81

Service & Maintenance

(2) Unit Serial Number:

(3) Unit “DL” Number (“design special” units only):

Final Process

For future reference, you may find it helpful to record the unit data requested
below in the blanks provided.

(1) Complete Unit Model Number:

(4) Wiring Diagram Numbers (from unit control panel):

— schematic(s)

— connection(s)

CSRA-SVX02A-EN 82

Trane
An American Standard Company
www.trane.com

Aftermarket Business Unit
3600 Pammel Creek Road
La Crosse, WI 54601

Literature Order Number CSRA-SVX02A-EN

File Number SV-CAP-Chillersource-CSRA-SVX02A-EN-0502

Supersedes New

Stocking Location La Crosse

Trane has a policy of continuous product data and product improvement and reserves the right to change
design and specifications without notice. Only qualified technicians should perform the installation and servicing
of equipment referred to in this bulletin.